This first picture comes from the episode, Balance of Terror and was shown on the bridge viewscreen. A closer look reveals the attention to detail on the makeup applied to actor Garry Walberg, aka Commander Hansen of Outpost 4.
The tunic that Walberg is wearing was also used in the episode Arena by an injured officer with burns on the left side of the face. The tunics emblem was also used on McCoy's tunic in the mirror universe of the episode, Mirror, Mirror. The "outpost" set Walberg is in was used two weeks earlier for the episode, The Naked Time.
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The makeup and hairstyling can be seen in more detail in this deleted scene
of actress Carole Shelyne from the episode, Arena.
The costumes sparkly design was so reflective that it caused numerous lens flares
appearing camera left of Shelyne.
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This next picture is from a makeup test for the disfigured Capt. Pike in the episodes Menagerie I & II. Jeffery Hunter was not available to reprise his role as Capt. Pike and so another actor was needed who resembled Hunter. As luck would have it, Sean Kenney (who played the navigator Lt. DePaul in the episodes Arena and A Taste of Armageddon) had a remarkable resemblance to Hunter.
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Drops of adhesive are applied to keep the makeup from separating from Kenney's face.
Buck Maffai played the giant anthropoid in the episode The Galileo 7. He weighed 400 pounds (181 kg) and stood 7 feet (2.13 meters) tall. Shown here for the first time is a close up of buck wearing the mask used in the episode. An alternate version of this clip can be seen in the Deleted Scenes section of this site.
Melvin Belli playing the "friendly angel" from The Children Shall Lead. The "sores" on his face appear to be glycerin with a colored center, causing the glowing effect when light refracts through it. This footage would be combined with other special effects.
The mold seam on Nimoy's faux ear can be seen here.
Witch make-up from Catspaw.
This clip shows two ventilation holes near the buttocks of the Gorn costume from Arena.
Thanks to Joe L. for the Catspaw clip.
Thanks to Dave T. for the Arena clip.