When an actor is too famous, looks too distinct or sounds too distinct to disguise their identity from the audience, cast someone to be the mask; in other words, bring on a different actor to play the character whenever they are wearing their disguise.
This way (one can only hope) the audience won't guess the secret, at least not until you want them to.
Although this is often done for villains, it is not limited to them.
Warning: This page contains spoilers! Read at your own risk!
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The Anime adaptation of Monster does this. To make the reveal that the pretty new girl in town is not Action Girl Nina, but Johan, her Half Identical Twin (who is also the series' Big Bad) in a disguise more shocking, the studio used Nina's voice actress to play Johan whenever they don this look. This is done both in the Japanese version and in the English dub.
In the English dub of Noein, Richard Epcar plays the title character, while Crispin Freeman plays Karasu, an alternate future version of Yuu, the show's main protagonist. When Noein removes his disguise and reveals himself to also be an alternate future version of Yuu (being almost exactly like Karasu, albeit with more evil intentions), he's suddenly voiced by Karasu's voice-actor Crispin Freeman. Averted in the original Japanese, where its Significant Double Casting all the way.
The unnamed Shinigami in the first Death Note Relight special. The ending hints that he might be the reincarnation of Light Yagami, but he isn't voiced by Light's VA in either the English or the Japanese versions
In Gurren Lagann, the narrator is revealed at the end to be an older Simon, but in both English and Japanese they have different VAs...except in the epilogue, which is how it's revealed in the first place.
In Eden of the East, Akira is informed about the Selacao by Hajime Hiura, Selacao number 5, who recreates for Akira the circumstances of his recruitment by Mr. Outside. On the recording, Mr. Outside's voice is the same as that of Hiura. This makes some sense as the series raises the possibility that any of the Selacao could be Mr. Outside/"The Supporer" and not know it due to Laser-Guided Amnesia. and the movies clarify that Hiura and Mr. Outside are different people. Hiura was recreating his experience, we're even shown him with the phone.
Pain has six bodies, and all but the female one speak with the voice one of them had when he was alive. Then it turns out, despite what we were initially lead to believe, he is not really in control either, he's just another corpse controlled by another person entirely.
When Tobi pretends to be Madara Uchiha, he is played by the same actor who would voice the later-shown real person. This is as much this trope as the creators of the anime not knowing that said character was a fake when the part was cast, but makes sense because it's established even the lowest ranking ninja are able to imitate voices flawlessly when using the Shapeshifter Technique (which also fits into this trope).
The Japanese version of YuYu Hakusho plays with this trope with the Masked Fighter. Judging by height and appearance, she is very obviously Genkai...but then she speaks with the voice of Megumi Hayashibara, causing confusion even beforeshe's revealed to be a young woman. She is in fact Genkai, but using her technique reverts the body to its prime condition.
Katsuhito Masaki, from Tenchi Muyo!, in all the various incarnations of the series, has his own voice actor, apart from his alter ego of Yosho.
In Steins;Gate, when supposed time traveler John Titor's text is read aloud he's voiced by Hiroshi Tsuchida in Japanese and Patrick Seitz, which hides the fact that he's actually Amane Suzuha, who just to add even more of a mask is in reality female.
Similarly used in Durarara!! during scenes where characters' screen names in chatrooms are given voice overs, which doubles as a case of G.I.R.L. for one character in particular, especially since the actors are shuffled at several points just to keep things ambiguous. It turns out "Setton" is Celty, usually played by a male actor when the character herself is female, "Taro Tanaka" is Mikado, "Bacula" is Masaomi; "Saika" is at first Saika-infected individuals then changes to Anri; and the main perpetrator of being a G.I.R.L., "Kanra," is Izaya.
Lupin III: Lupin (and other characters) are usually voiced by the character they're disguised as. Occasionally lapsing into lines with their regular voice actor, reminding the audience who it really is.
Special note for Lupin Family All Stars, where the disguise of the "man in the iron mask" is voiced by Chikao Ohtsuka, who voiced Zenigata in the 4:3 version of the pilot film and Goemon in the 1971 "Green Jacket" series. Makio Inoue and Goro Naya were voicing the Goemon and Zenigata characters, respectively.
In the film version of A Scanner Darkly, Mark Turner plays "Hank", who is later revealed to be Winona Ryder's character, Donna.
The writers of DCAU Batman LOVE this trope. In Batman: Mask of the Phantasm, the titular Phantasm is initially voiced by Stacy Keach, who also plays Carl Beaumont. This is a red herring, however, as the Phantasm turns out to actually be Andrea Beaumont - Carl's daughter - using a voice modulator to sound masculine.
And also in Batman: Mystery of the Batwoman, where Kyra Sedgewick voices the titular Batwoman, but none of the suspects for the identity. This turns out to be because ALL of the suspects are the Batwoman, using a voice modulator to sound the same.
We Are the Strange does this. It's possible that the voice that speaks thorugh the SinisteRRR game (which is actually the voice from Sinistar), is also HIM Big Bad who is played by M dot Strange (the director), However, the film is really really confusing, so it's hard to tell if this really is an example or not.
For all the viewer knows, SinisteRRR is just The Dragon and is simply repeating a mantra that HIM taught it.
Film (Live Action)
The Adventures Of Captain Marvel: To keep audiences from figuring out which of the scientists is secretly the Big Bad, the studio brought in Gerald Mohr to do the Big Bad's voice all the way up to The Reveal. Really comes in handy when the scientists start getting killed off and the # of possible suspects is eventually narrowed down to just two.
Spoofed in Casino Royale (1967), where Woody Allen's character Jimmy is revealed to be Dr. Noah, the Head of Smersh despite his voice not even remotely sounding like Valentine Dyall, who voiced the doctor all the way up until that point.
In Psycho, Anthony Perkins doesn't play Norma Bates until the very end of the film. Up until that point, the role was assumed by several different actors.
In the 2007 David Fincher movie, Zodiac, no less than 3 different actors (Richmond Arquette, Bob Stephenson, and John Lacy) are used to play the titular killer (always seen either wearing a mask or as a silhouette). Late in the film, a potential suspect is revealed and is played by Charles Fleischer. Despite his looking nothing like the 3 Zodiac actors, the film never 100 % clears him. The last we see of him, the possibility that he could be the killer is still somewhat open.
Also, John Caroll Lynch plays Arthur Leigh Allen, probably the most famous Zodiac suspect. However, Lynch matches the basic body type of the 3 Zodiac actors, so he's not as dramatic or as shocking of an example as Fleisher is.
A deleted scene in Secret Window (that was not from Johnny Depp's perspective) shows Shooter (played by a very recognizeable John Turturro) starting a fire. Due to The Reveal, this means that, instead of playing Shooter, Turturro is actually playing Depp's character. The director thought having Turturro appear in a scene with an objective POV wouldn't make sense in this context, thus the scene was removed from the film. The only scenes where Turturro appears in the final cut are from Depp's perspective.
In Velvet Goldmine, Jonathan Rhys Meyers' character, Brian Slade, reinvents himself as a music star by the name of Tommy Stone; a different actor is used to play Tommy Stone in order to hide the surprise.
A vocal variation of this was done in the The Lord of the Rings movies. In the scene where Gandalf reveals himself to Legolas, Aragorn, and Gimli in Fangorn Forest, they took both Ian McKellen and Christopher Lee's voices saying the exact same lines and masked them over each other to hide just which of them it was. According to DVD bonus material, the two of them were asked to imitate one another for at least some of those lines.
In High Plains Drifter, there is a deliberate ambiguity as to the identity of the Stranger played by Clint Eastwood. He might be the brother of the murdered marshal, or there might be a supernatural explanation including but not limited to him being the ghost of the marshal, Satan, or an angel. When the marshal's murder is shown in flashbacks, he's played by Buddy van Horn, a stuntman who doubles for Eastwood and looks a lot like him (but different enough to aid the ambiguity).
In Sherlock Holmes, the actor providing the voice for Moriarty is uncredited, and it is unknown who it is (The Other Wiki indicates rumors of it being Brad Pitt, although an Ed Tolputt is credited as "Anonymous Man", so it might be him). In the sequel film, the character is played by Jared Harris.
In Kamen Rider X Super Sentai Super Hero Taisen, Kamen Rider Decade and Gokai Red disguise themselves as Kamen Rider 1 and Akaranger respectively, which is somewhat consistent with their usual powers (though Decade had never transformed into a Showa-era rider prior to that). What isn't consistent however, is that they also take on the voices of Kamen Rider 1 and Akaranger (as well as Decade copying Rider 1's belt, with the Decadriver only appearing when he reveals himself).
Keeping with the theme of misdirection, The Prestige managed to avert this and still completely surprise everyone. Turns out that Christian Bale plays identical twins, Albert and Frederick Borden, but both of them alternate being constantly hidden under a disguise, and never really say much or even stay in shot. When Bale without the disguise is in a shot with his disguised twin, a double is used. Thanks to a lack of dialogue for the disguised "Fallon" and his completely unremarkable nature and behaviour, no one suspected he had a secret at all, but then this is Christian Bale we're talking about.
Live Action TV
Used for a plot twist near the end of A Warning To The Curious where the ghost (John Kearney) tricks both the protagonist and the audience by disguising as Dr. Black, and, for that scene, is appropriately played by Black's actor, Clive Swift.
The first appearance of Commander Sela in Star Trek: The Next Generationin the episode where Geordi is kidnapped and brainwashed by Romulans had her standing in the shadows, and played by a different actress (although Denise Crosby did provide the voice). Notably, Sela has black hair in this first appearance — at the time of filming they hadn't settled on making Sela blonde to emphasise her half-human heritage.
Kamen Rider does this a lot. The human and Monster of the Week forms of the bad guy usually have the same actor...except when The Powers That Be need to hide who the bad guy is. Never an in-story reason for the voice changing happening sometimes but not other times.
In the Doctor Who serial Remembrance of the Daleksthe Renegade Daleks use a young girl as the "imagination" component in their battle computer. When seated in the computer's chair, she is voiced by a Davros-impersonating John Leeson—the chair is very Dalek-like in its appearance, and the voice fooled viewers into thinking that Davros was leading the Renegades.
The Fresh Prince of Bel-Air: The episode "Fresh Prince: The Movie" had Will tell about John "Fingers" O'Neill (played by Brad Garrett) coming after Will and the Banks family after Will witnesses a mob killing. It was all a Batman Gambit by Will and Carlton to hustle Jazz out of his poker money. While it works, Fingers returns to where Will is, and Will runs and screams in terror. "Fingers" reveals he was really Jazz in disguise this time, out for a little payback for Will hustling him.
Person of Interest in what may have been a simple recast, had archenemy Root played by one actress in the character's debut, with the Camera only showing glimpses from odd angles, or her hands while typing... in the season Finale she was played by a second actress Root pretends to be a PoI to get close to Finch, as both actresses are fairly well known it is more likely intentional.
AREM (voiced by Bob Lutrell) is an alias Robert Mitchell (voiced by Steve Burns) uses in Adventures in Odyssey. Justified in that AREM is a computer voice Robert uses to hide his identity.
The main gimmick of the Big Finish Doctor Who audio "The Maltese Penguin" is that the Shapeshifter main character, Frobisher, takes on the form of the Sixth Doctor throughout the majority of the story, meaning most of his dialogue is performed by Sixth Doctor actor Colin Baker imitating Frobisher's exaggerated Boston accent. It's especially obvious that it was done for the fun of it by the fact that no confusion between Frobisher and the Doctor ever comes up - everyone immediately knows who he is and the actual Doctor is comfortable with it, and even shows up as a Drop-In CharacterTalking to Himself at times.
Ingeniously played with in the stage version of Witness for the Prosecution. The cast list includes "The Other Woman," and the audience is led to believe that this is the old woman who gives evidence to the lawyers. Nope; the old woman is Romaine in disguise, and is played by that actress, while "The Other Woman" appears several seconds after that reveal. She's Leonard's lover.
The RED Spy when he's disguised as BLU Scout in Team Fortress 2's "Meet The Spy" video is voiced by the latter's VA until The Reveal. In-game, when a Spy is disguised, he also sounds identical to his disguise due to this trope.
A very odd inversion occurs in Myst IV: Revelation. Pretty early on, it's established that Sirrus (Brian Wrench) is still evil and that you'll ultimately have to fight him. While this is technically true, by the time you face off with him he's now disguised as Yeesha and is thus now being played by Yeesha's actress, Juliette Gosselin. It's also notable in that The Reveal is done without the non-mask actor being shown.
In the first Icewind Dale game, John Kassir plays Belhifet, while David Ogden Stiers plays the narrator, who is later revealed to be Belhifet. Then, for good measure, once The Reveal is made, the character breaks into a fit of demonic laughter and (for his remaining 20 seconds of screentime) is played by Jim Cummings.
Another Bioware title, the first Baldur's Gate game, does this too. When Sarevok, first approaches you as his alias, Koveras, he just uses one of the stock voices you've already heard several times earlier in the game ("You need something, stranger?").
However, if you're fast enough to click on him as he is leaving, you'll hear Kevin Michael Richardson's very distinct voice instead.
In BioShockAtlas and Frank Fontaine are voiced by two different people.
And in Bioshock Infinite, Booker and Comstock have different actors, despite the fact they're alternate reality versions of the same person. Somewhat justified since Comstock is an older version of Booker.
An episode of U.S. Acres had a character who looked and sounded like Orson Pig (voiced by Gregg Berger), but is later revealed to be Lanolin (voiced by Julie Payne) wearing a mask.
The episode, "Almost Got 'Im" in Batman: The Animated Series focused on a meeting among various members of the rogue's gallery as they swap stories. Near the end, it turns out that Killer Croc is actually Batman in disguise, despite Croc clearly being played by his regular voice actor up until that point.
And when he says those words to Robin (Tim Drake) in explaining just how he'll get away with impersonating Batman while Batman himself is missing, he does so using Robin's voice. Which creeps Robin right the hell out.
Which makes sense when you consider a specific trope that Superman named. In that instance, Superman spoke of staying in control and keeping himself in check at all times. Certainly he's had time to practice what he can actually do with that control.
Well, that, and it's a shout-out to the early days, when the explanation for why nobody knew Superman was Clark Kent was that he used "precise muscle control" to re-shape his face.
From the same series, the Crybaby Clown, voiced by Mark Hamill, is really Baylon Hotner voiced by Matt Lanter.
Usually the Scooby-Doo villains will have their same voice actor, even when in disguise. There were a few exceptions, in the episode "A Gaggle of Galloping Ghosts", when the female gypsy fortune teller (voiced by June Foray) was revealed to be a man named Big Bob Oakley (voiced by John Stephenson), and on the episode "Scooby's Gold Medal Gambit", the Master of Disguise The Chameleon disguises himself as Scooby-Doo at one point in the episode, and his disguised voice was provided by Don Messick instead of his regular voice actor.
As an effort to be as realistic as possible, What's New, Scooby-Doo? played this straight though, with the voice of nearly every monster (that was credited, anyway) played by someone other than the voice of the person in the costume.
In the Rocko's Modern Life episode "Pranksters", Filburt (voiced by Doug Lawrence) impersonates Rocko's grandmother as an April Fools' Day prank on Rocko and Heffer. When in the disguise, "Granny Rocko" is voiced by Carlos Alazraqui (essentially doing a cranky, higher-pitched version of his Rocko voice).
The Simpsons has played this straight in "The Great Money Caper" (Grampa Simpson, voiced by Dan Castellaneta, disguises himself by means of a latex mask as a judge, and speaks in a Judge Snyder-esque voice by Harry Shearer) and "The Frying Game" (the old lady Homer thought he killed, Mrs. Bellamy, was voiced by Frances Sternhagen, until she revealed herself to be Carmen Electra in a Full Body Disguise).
Though to be fair, the Simpsons did avert this a few times, such as when Otto disguised himself as the State Comptroller in "Lisa Gets an 'A'", Harry Shearer (Otto's regular voice actor) still supplied the fake State Comptroller's voice, even though it still sounded radically different from Otto.
In the appropriately named The Transformers episode "Masquerade" five Autobots impersonate the captured Stunticons due to "camouflage paint." Windcharger becomes "Wildrider," Jazz becomes "Dead End," Mirage portays "Drag Strip," "Breakdown" is played by Sideswipe and Optimus Prime mimics "Motormaster." Before they go meet Megatron in disguise, "Drag Strip" is voiced by Frank Welker and "Motormaster" by Peter Cullen (the respective voice actors of Mirage and Optimus). When in disguise around the Decepticons, "Wildrider" is voiced by his usual voice actor, Terry McGovern, while "Motormaster" is played by Roger C. Carmel, Motormaster's voice actor.
The animated version of "The Mask" had a group session where Dr. Newman had the villains who fought the Mask recount their experiences. However, it's revealed the real Dr. Newman was caught in traffic and unable to come, while the Dr. Newman with them was actually the Mask. Ben Stein voiced Dr. Newman before the reveal and with a smarm briefly returns as the Mask-as-Dr. Newman says "Although I play one on TV" (earlier, the Mask admitted he may not be a doctor).
The 1980s Teenage Mutant Ninja Turtles used a "Freaky Friday" Flip to swap the minds of Shredder and Master Splinter in one episode. While they thought in their "real voices" with their appropriate voice actors, they still publicly "spoke in character"—Shredder was still voiced by James Avery and Peter Renaday still voiced Master Splinter.
In the Batman: The Brave and the Bold episode "Scorn of the Star Sapphire!", Sapphire is voiced by Vicki Lewis (with an English accent), Carol Ferris is voiced by Rachel Quaintance, and there's also an English-accented reporter who wears purple voiced by Eliza Schneider. As per the comics, Carol is Sapphire, although she uses the reporter as a decoy.