In college I made a full-body, hot pink and tan gorilla. I built the whole thing out of 3/4 inch sheet foam, using (actually, lucking into after some trial and error) the "wedge method" that Buck Beaver details in his wonderful puppet building tutorial on his website. I built gorilla feet using a pair of old sneakers as the base and some sculpted box foam. I used spray paint to give the whole suit a base "skin tone" (I don't remember what I used, but the paint didn't degrade the foam) and attached strips of tan and hot pink dyed burlap strips for "fur." (This was for a stage show, and was made with whatever was laying about, as we had no budget.) A talented artist in the theatre program named CJ sculpted the head out of sheet foam and a hard hat. Originally, we wanted the jaw to be practical (and it could have been easy - with a "Sweetums" like apparatus) but we ran out of time and materials.
There is a photo of this creation on my alma mater's web site, I see if I can find it and post a link to it.
--Scraps