Did he get fat?
I found a picture from a party at Ybar here in Chicago, ( Danny Masterson is also there) . It's about 2 days old, and I wasn't sure, but it looks like him only "Chubbed up". The nose definitely looks the same. I didn't know if he pudged up to play Ponch.
Chicago-Scene photo: http://www.chicago-scene.com/2007photohtm/Y-Bar-Wed-b.htm
Scroll down to photo #19