Del,
I've gone through all my issues of HM - I have a full set, including the only 'on-line' issue (that I'm aware of). I cannot find the article, for love or money, but I know I NEVER loaned any of them out. It bugs me that I got your hopes up and now I can't deliver.
As I remember, Alan sculpted the ruff on a circle of styrene for solidity. When it was dry, he then carefully super-glued thin lead wire on edge, probably for the seam/edge. I believe he cut it from the styrene and attached it to the shoulders of the figure, then added the head to the gap in the middle. I'll keep looking, but now it bothers me that I can't find the article - and the issue.
As to my Shakespeare project: I did find my project notes detailing more frustrations than triumphs, but I did get it completed in time for SCAHMS 2009 and got a silver for it. I did try to sculpt a ruff using Alan's technique. After botching two of them, I gave up and gave 'Old Will' a more conventional, Elizabethan collar.
I'm sorry I couldn't deliver the goods.
Jim