I usually draw their faces mulitple times till I'm satisfied, since their faces are where their design really happens in my art style.
This guy, Leo, has actually been redesigned about 11 times since he was created in 2005. ...Probably more than that actually, he's my go to guy to play with new art styles with, so he looks different a lot. This is my favorite out of all of his designs though.

This is Tory, from my webcomic Long Shot . I was having a lot of difficulties with his face, since he's supposed to look similar to another character, but different enough. As I kept drawing, I scrapped that idea, and just drew him however I felt. xD The third face is the best one, and now his design.

Those are my most recent character designs...that I'm willing to share. My process is very messy and not pretty to see. Haha.