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Thin, Curved Ears?

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I'm still working on Happy, who is an original species of mine so I don't really have other people's fursuits to look at for help on this, and he has some strange ears.





My original plan for his ears was to make the shape out of plastic canvas and slip the sleeve of fleece I've sewn for the skin and colors over it, but no matter what I do to the canvas when I shape it, it takes on sharp little puckers and corners that will be easily visible through the fleece. I need something that can be shaped but still be stiff when it's done so his ears don't flop over or anything.

Long story short, they're somewhere between rabbit and deer slightly curled back but I can't find anyone with a method that would work to make them. Any ideas?

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