10 Times Prosthetics Nearly Broke An Actor

10. John Rhys-Davies - The Lord Of The Rings

John Rhys-Davies' portrayal of the dwarf warrior Gimli in Peter Jackson's The Lord of the Rings trilogy was one of many iconic turns in the Middle-earth film series.

However, playing the famously grouchy character came at quite a cost.

After the various prosthetics and make up were applied to his face - which would take around five hours to finish - Rhys-Davies started to feel a little odd. As it turned out, the prosthetics were causing an allergic reaction which eventually led to the skin under his eyes burning. Ouch!

The actor eventually powered through and convincingly brought the son of Gloin to the big screen, but his traumatic time in the make up chair may have put him off roles like this again in the future.

Rhys-Davies even admitted that he was offered the chance to return to Middle-earth for Jackson's Hobbit series, but turned down the offer, saying, 'There's a sentimental part of me that would love to be involved again. Really I am not sure my face can take that sort of punishment any more.'

It looks like he dodged a bullet in the end as The Hobbit trilogy ended up being nothing more than a failed attempt to stretch one beloved book into an epic three movie saga.