Producers Disney hired prosthetics expert Guillaume Castange from France who spent months remodelling the character actor's face -- first on computer and then with specially designed prosthetic pieces.
Kher had to spend almost five hours getting into make-up.
His transformation was so dramatic that while filming in Film City, his wife Kirron Kher who was also shooting nearby, failed to recognise her husband! To maintain secrecy about his look, the call sheet would list the name of Anupam Kher as Samar Singh, so that nobody knew it was the actor in disguise!