First I did a few quick sketches of what the makeup could look like, and let the director choose what he liked.
I then took an impression of the actor's face.
If you recognize that hair in the foreground, it's because it belongs to the lovely model of my first old age makeup. She's now the Aunt Jack to my Uncle Frank (Mrs. Doubtfire, anyone?).
I sculpted the makeup on the plaster copy of his head. This is the sculpt before the finishing touches, which come right before the mold is poured.
And then made molds of both pieces (the side of the face and the nose).
They were cast in gelatin and applied in about two hours on set. The original plan was to have blood or pus coming out of the broken blisters, but the director and cinematographer liked it without. I think it turned out pretty well, regardless. Of course, in the end, the one shot the makeup was needed for turned out to be pretty dark, so you couldn't see much of it anyway.
Oh well. It was still a great experience. Listening to people's reactions to seeing him for the first time was worth it, alone. The actor, Richard Halverson, was very tolerant of the whole process and great to work with, as well.