http://www.tky.3web.ne.jp/~ghostman/apeman.html
The text is all in Japnaese, but it shows a pretty good step by step of what it takes to make a good mechanical ape head.
The clay sculpt.
Foam latex or silicone gel face, ready for the hair application.
Fiberglass underskull. Here you can see the black elastic that keeps the jaw closed until the actor opens it, the acrylic gums and teeth, and the "lip bars" that peel the lips back via a sort of "figure 8" cable arrangement, when the actor opens his mouth.
Underskull with mouth open. See how the lip bars pull back as the jaw opens wide.
Finished mask, with hair in place, fitted over the underskull w/ glass eyes inserted.
We won't talk about the bodysuit...
The suave hominid about the savannah.
"Cheeeeeeeeese"!
Enjoy!
-Sarge
The bodysuit looks pretty frumpy but that head is mighty slick!
-Sarge