By the time Congo came along, some of those problems with silicone had been overcome. As a skin material, silicone was more flexible and 'stretchable' than foam rubber; and advancements in radio technology allowed for more points of movement to be achieved with fewer mechanisms. Except for wide-mouthed screaming -- which would be realized with a separate head built specifically for that purpose - all of Amy's facial functions and every expression could be performed by a single head. That enabled Frank Marshall to direct Amy just as he would any other character in a scene, without having to wait while the effects crew switched from one head to another. Stan Winston's crew built a second fully articulated head to fit the larger skull of ape behaviorist, Peter Elliott, who would perform some of Amy's more demanding actions. The studio also built two non-mechanized Amy stunt heads for long shots where the movement was not required. All of the Amy heads could be attached to a multi-layered suit that included an underlying muscle suit, which transformed Lorene Noh's human physiology to a more muscular gorilla form, and an outer hair suit, covered in hand-punched yak hair. Aluminum and steel arm extensions inserted into the muscle suit gave the limbs the appropriate ape-length.

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