If he is not broken into parts, then it might be hard to facepose him. His eyebrows, beak, teeth, and tounge need to be seperate pieces If I'm gonna get them to look right, and seeing his design, I think he'll need just one bone. so weighting him will be fast. Should his phymodel just be a ball, or a copy of him? I think a ball might be better, but then his beak and tail and such will clip through the floor. Also, how big do you want him to be? can you post a picture of him next to a person so I can scale him to that size? or do you want multiple sizes?
do you got blender or 3ds max? I think u could make the phys ball little bigger then it so it don't cause clipping. I got it the size I want it to be all ready I just need faceposing and rigging.
Edited:
eeyup