Whether it was embarrassing or just painful, the cast of LOTR have had their share of ouches.
This quote is from Sean Astin, who discusses his most embarrassing moment (and what I call painful).
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I had so many embarrassing moments while filming the The Lord of the Rings trilogy. One of the worst is from the third movie. I was sitting in Rivendell, an elf paradise, and an 80-pound wooden prop fell and landed on my head. The crew raced over and picked the thing off my head and I came to. A lump started growing, and the wig that was glued to my head lifted up and started pulling off. I got a CAT scan and luckily, I had no brain damage. The neurologist said I had a very large head, though. I'm proud about that.
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This next one is quoted from a magazine about Viggo Mortensen and consequences of surfing.
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During production in New Zealand, many of the hobbits, led by Elijah Wood, became surf fanatics who spent their downtime riding waves. Mortensen joined them one weekend, but instead of hanging 10, he banged his head when his board flipped over and hit him. On Monday, Mortensen showed up to shoot the Mines of Moria scenes, but the right side of his face was badly swollen, with his eye shut like a punch-drunk boxer's. When makeup artists couldn't cover the bruising, Jackson was forced to shoot Mortensen only from his left side.
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I have also heard that Orlando Bloom broke a rib falling off a horse during filming, and Sean Astin also punctured his foot stepping on a stick.
These actors went through a lot during the filming of LOTR, but I'm sure they didn't regret it once.