10 Actors Who Endured Extreme Pain and Brutal Makeup for Their Roles

Naomi Grossman as Pepper — 'American Horror Story' (2012–2014)

Naomi Grossman underwent a dramatic physical transformation to portray the character of Pepper, shaving her head and wearing facial prosthetics. This made it difficult for her to use natural expressions, as her features were altered to such an extent that even basic emotions became challenging to convey. It is fair to say that playing Pepper was a particularly demanding role for her.

Gary Oldman as Winston Churchill — 'Darkest Hour' (2017)

For his portrayal of Winston Churchill, Gary Oldman underwent extensive physical transformation using special body makeup and prosthetics. As a result, he found it difficult to stand or express himself naturally due to the heavy layers of makeup and clothing. The demanding process also made breathing uncomfortable during filming. Despite these challenges, he persevered and ultimately won the prestigious Oscar.

Oscar Isaac as Apocalypse — 'X-Men: Apocalypse' (2016)

According to Oscar Isaac, wearing the Apocalypse suit was incredibly uncomfortable due to its weight and the restrictions it imposed, which limited almost all movement. He was also required to wear tall shoes and could not move his head freely, significantly hindering his interaction with other actors. Additionally, the suit produced a continuous humming sound, which meant his voice had to be dubbed after filming. Removing the prosthetic makeup was equally difficult and painful, as layers had to be peeled off his skin.

Doug Jones as the Faun / Pale Man — 'Pan’s Labyrinth' (2006)

Despite being known for playing creatures, Doug Jones faced greater challenges with his dual performances in Pan’s Labyrinth. As the Faun, his costume included large horns and complex leg pieces, making it impossible for him to sit comfortably, so he often had to doze off in awkward positions. His Pale Man costume also required long hours to apply, which led him to take short naps while still wearing parts of it.

Jessica Chastain as Tammy Faye Bakker — 'The Eyes of Tammy Faye' (2021)

To portray Tammy Faye Bakker, Jessica Chastain underwent a demanding process of applying makeup and wearing numerous prosthetics that evolved throughout the film. She had to wear multiple layers of facial prosthetics along with a wig and heavy costumes, which created a suffocating effect. The intense makeup made breathing difficult and restricted her movements, leading to anxiety during her initial tests.

John Matuszak as Sloth — 'The Goonies' (1985)

John Matuszak, a former NFL player, had to spend nearly five hours each day applying makeup to transform into the character of Sloth, using 15 different prosthetic pieces, including an artificial eye. The thick makeup made it difficult for him to speak and left him drenched in sweat throughout filming. He also had to keep the prosthetics in perfect condition at all times, and any disruption, such as water splashing during scenes, meant he had to redo the entire makeup process.

Bolaji Badejo as the Xenomorph — 'Alien' (1979)

The physical effort required of Bolaji Badejo for the role of the Alien was considerable, especially given the lack of dialogue. Visibility inside the costume was extremely limited, forcing him to rely on small gaps to navigate. The tightness of the suit trapped body heat, leading to excessive sweating. As a result, he could only wear the costume for short periods.

Tim Curry as Darkness — 'Legend' (1985)

The role of the Lord of Darkness, undertaken by Tim Curry, involved some of the most complex and elaborate makeup ever created at the time. This was largely because his costume included massive fiberglass horns attached via a harness, which placed constant pressure on his neck and spine. The process of applying the makeup took around eight hours, while removing it required an hour-long bath, as it was glued to his body. At times, the discomfort became so overwhelming that he would peel the makeup off his face and skin in frustration.

Lon Chaney Jr. as Larry Talbot / The Wolf Man — 'The Wolf Man' (1941)

The process of Lon Chaney Jr. transforming into the Wolf Man was extremely difficult and remains one of the most challenging feats in the history of early Hollywood makeup techniques. Yak hair was glued to the actor’s face and then burned with heat to create the illusion of a smooth transformation, causing considerable pain. Removing the makeup was even more uncomfortable, as the adhesive substances used to hold it in place had to be forcefully stripped off after a full day of work.

Jim Carrey as the Grinch — 'How the Grinch Stole Christmas' (2000)

The transformation process for Jim Carrey to get into the role of the Grinch is well known and was not easy, taking between three and eight hours per day in the makeup studio. The costume, made out of itch-inducing yak hair, damaged his skin, and the special contact lenses were extremely uncomfortable. He even experienced panic attacks at one point because of how suffocating the costume was. A person trained by the CIA taught him resistance techniques normally used during torture.