We Used 2500 Pounds of Clay to Sculpt Our Kong Animatronic!
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What this video covers
Distortions Unlimited takes viewers on a comprehensive 43-minute behind-the-scenes journey through the creation of their Kong animatronic gorilla head — a massive professional-grade figure that stands approximately 11 feet tall when raised. The build is documented from initial metal armature construction through clay sculpting, latex skin application, foam filling, mechanical rigging, and final paint and finishing. Sculpted by company founder Ed Edmunds as a passion project, Kong features articulated mouth, head-turn, and independently moving eyes and eyelids, driven by heavy-duty cylinders. The finished prop ships with a control system, audio track, amplifier, fog machine, and simulated lightning lighting effects.
Key takeaways
- ◆The Kong head stands approximately 11 feet tall and is built on a heavy-duty metal armature covered in clay-sculpted latex skin with foam fill
- ◆Articulation includes mouth open/close, left-right head turn, and eyes that pan and blink independently
- ◆The full production pipeline — armature, sculpture, skin, mechanics, paint, and effects integration — is documented in a single extended video
- ◆Distortions Unlimited has over 45 years of professional monster-making experience in the USA
- ◆The finished animatronic includes a bundled control system, audio track, amp, fog machine, and lightning lighting effects
Who this is for
Professional haunt operators, theme park buyers, and serious animatronics enthusiasts who want an in-depth look at how a world-class studio engineers and sculpts a large-scale creature prop from scratch.
Materials mentioned
- • clay
- • metal armature
- • latex
- • foam
- • professional-grade cylinders
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