Traditionally in the show, the horses are people carrying/wearing wire or cane 
or other cage-like pieces to give the impression of horses rather than create 
anatomically correct horses or, ghod forbid, panto horses! I have also seen it 
done with papier mache heads and conical cups around the ankles.

I did make some hooves for a costume (Satan) about ten years back. They were 
carved from light timber (pine) in four sections then glued and screwed before 
painting. The inside shape was similar to a high-heel shoe so that the foot sat 
with the heel higher with the foot at a diagonal, not the most comfortable 
solution but the most appropriate for scale -- remember you hoof must sit well 
visually against the ankle. These hooves were then strapped around and up the 
ankle. I wanted the clip-clop sound so avoided some sensible rubber on the 
bottom but did place some grooves there to give a little traction.

The main thing is to closely look at a horse hoof to see how they look, get the 
profile right, and remember the underside which has a lot of shape and texture. 
You can hide the ankle strapping under some hair -- think Clydesdale but not so 
thick,

-C.


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