The entire cast of the trilogy had to wear wigs to put on the likeness of the character they were portraying. The only exception to that rule was Peter Jackson’s son, Billy.
The boy was just a toddler at the time and was filmed listening to Bilbo Baggins’ story at his birthday party. Wide-eyed and full of awe, the little kid’s natural hair was as hobbity as can be.
Break a Leg
Remember when Aragorn kicks the helmet after realizing what happened to Merry and Pippin? Remember the pain in his voice when he shouted in frustration? Chills. Well, apparently, the pain wasn't just a display of brilliant acting.
When kicking the helmet, Viggo Mortensen broke two of his toes and channeled his pain through it, which made the final cut. Only after cutting, director Peter Jackson realized the pain was real. Mortensen, however, was much more impressed by the stunt crew, who kept performing with injuries worse than his.
Little Dwarf, Big Tree
John Rhys-Davies played, Gimli the dwarf, aka the shortest character in Tolkein's trilogy. But he also lent his voice to a literal tree. Treebeard, in case you need a little memory jog, was the oldest of the ents — a Middle Earth species that is, in essence, a walking, talking tree.
Curiously enough, the actor didn't need any digital intervention to achieve Treebird's low vocals — he simply spoke through a wooden megaphone using his lowest possible register.
A film with so many stunts and battle scenes is bound to have its fair share of injured performers. One scene actually had all-injured performers powering through it.
The performers in question were Orlando Bloom (Legolas), Viggo Mortensen (Aragorn), and Brett Beattie (who did the stunts for Gimli). The scene shows them chasing the Orcs, and doing so with broken ribs (Bloom fell off a horse), toes (Mortensen broke a couple kicking a helmet), and a knee injury (Beattie). According to Peter Jackson, the guys yelled in pain only after the scene was cut. Now that's what we call dedication.
Taking a Bow
For some reason, the scene at the end of "The Return of the King," when Aragorn bows down in respect for the hobbits, didn't require the physical presence of Viggo Mortensen on set. (Cinema magic. Don't ask us how.) The actor, however, came in nonetheless.
And even though he didn't have his character's crown, he made a paper crown. Cast members kept decorating and adding to that crown in between takes, which resulted in extremely giggly actors fighting to keep their composure with each successive shot.