Applying prosthetics to the actors' faces
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Transcript
Richard:
The gelatine is cast out of a mould and every day we glue these little prosthetic tips onto the end of the actors' noses to make them look as though they've got a slightly larger nose. That simple job though, took about an hour and a quarter to glue onto the actor's nose.
Here we've got a much more complex prosthetic. John Rhys-Davies, who played Gimli, wore a silicon prosthetic every single day. You can see that the skin of the prosthetic has an extremely skin-like quality. If we zoom in on that, you can see how, um, it's very, very malleable.
And if we get Gino to just sit it against his face, even without gluing it on, and if he moves his features, you can see how the skin moves really beautifully. Ah, so this would take minimum of 4 hours to glue on every day, so poor John Rhys-Davies had to sit in the seat for 4 hours to have this glued to his face.
And then the orcs, we used a much simpler process which is just foam latex. I'll have Gino hold that one up too. And these were glued on and painted. And we did five or six orcs every day in this process, over the length of the film producing over ten thousand prosthetics to create the characters that you saw on the screen.

