"His size didn't match identically, but it didn't matter," says costume designer Ellen Mirojnick of Robert Downey Jr. "In his body language, he 'became' Chaplin."

Richard Attenborough's decision to use footage from Charlie Chaplin's films greatly heightened the challenge of bringing him back to life in the same movie. "It set up the most terrifying prerequisite of physical similarity," the director says. "We had to find someone who's 5'7, dark, ravishingly handsome, in his 20s, and an extraordinary physical actor." Robert Downey Jr. was cast, and Chaplin's makeup and wardrobe teams went to work researching the great comic's bios, especially Maurice Bessy's Charlie Chaplin. The actor's fourth wife and widow, Oona, gave the production access to his personal files and picture collection.

Makeup and wardrobe payed special attention to Chaplin's most recognizable screen incarnation - his Little Tramp. Downey's hairline was modified to reflect Chaplin's comical coif, and he was outfitted with six handwowen mustaches. His suits were cut for Chaplinesque movements. "They're short in the armhole, they had to hike up, and the pants had to have fullness," says costume designer Ellen Mirojnick. A replica of Chaplin's bowler was custom-fitted for Downey while keeping the proportions. "It wasn't exact," admits Mirojnick. "Chaplin's might have had a different brim. The important thing was to create an accurate illusion."

   

Diane Lane portrays Chaplin's third wife and Modern Times costar, Paulette Goddard. Kevin Kline plays silent star Douglas Fairbanks. "He was the Hollywood version of the Duke of Windsor," says Mirojnick.