How cone Mickey rourke is so normal lookin in this??

Err make-up?

Probably because he isn't infront of the camera a lot in this movie, so therefore he's not as noticeable.

He was on his way to the way he has looked the last few years but this is 10 years ago... Also, as said... Hollywood magic. Actors can be made to look almost anyway they want, good or bad on film.