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 The
make-up was designed by Michael Westmore, the show's make-up
supervisor. "From the start, the producers wanted the character
of the Kazon race to be such that it would fill the role of
the Klingons on previous Star Trek shows, but they must
clearly not be Klingons. The new villains would appear in the
very first episode, the two-part story
"Caretaker". The Kazon
were written as cruel and barbaric, without the sense of
honour that Klingons are known for. To illustrate these
traits, make-up took a forehead based on an almost devilish
structure, and the "comb" that runs down the forehead was
modelled on the look of the vulture's neck. In later episodes,
the make-up department took the "vulture neck" from the "comb"
and built an appliance for the Kazon neck. In addition, they
created a new nose tip which lengthened the actors' noses and
added spikes coming out from below the nostrils. To
distinguish the Kazon even further from the Klingons, the skin
colour was made a burnt orange instead of dark brown."
 Joseé
Normand, the show's hair designer, created the Kazon hair
using some unusual ingredients including sponges and dried
pig's ears (the kind sold in pet shops for animals to chew
on).
She says: "I wanted the hair to look like something that came
from another planet, something really big and menacing, and
that's what I came up with. I used pigs' ears and sponges.
Some people liked it, some people hated it, but it's
different!"
Alan Sims, the show's properties master: Kazon weapons were
crude, yet futuristic, weapons that had to convey the
barbarism of the Kazon. These rifles and pistols looked
antiquated even though they're 24th century. I used copper
tubing and bent copper joints that ran to a barrel-head that
was a different shape than the phaser rifle. The copper tubing
became the body of the unit itself and was attached to a
leather strap over a wood-looking grip that had a completely
different presentation. It actually looked like a plumbing
nightmare, but the prop worked because it helped define the
Kazon."
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 The feeling was that the best direction for us to go in terms of trying new things to be socially reasonable to represent something Star Trek has always been, which was to go for a female captain. The studio wasn't totally convinced that, and we agreed that we would also look at male actors and be sure that we kept an open mind. When the casting process was over the selection that was made was one wonderful French Canadian actress named Genevieve Bujold. Who got the job.
 She's
a very very good actor and I am sure that if we had been doing a
motion picture she would have been phenomenal but there was enough
going on in that first day or two that we realized that for everybody's
sake that it was best to go in another direction.
 When we went back to the drawing board, and the first runner up had always been Kate Mulgrew. She was always someone I had been very fond of and so had the studio, and Mike and Jeri. And luckily Kate was still available and we struck a deal within a week or so and we were back in production."
From Voyager Season 1 DVD (Bonus DVD Easter Egg)
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