19 – The Tin Man’s makeup almost killed him.
The role of the Tin Man in the Wizard of Oz originally went to Ray Bolger (who actually ended up playing the Scarecrow) and then to an actor named Buddy Ebsen. Ebsen had already completed four weeks of rehearsals and recorded all of the Tin Man’s songs when there was an issue with his makeup.
In an attempt to make the Tin Man as shiny and silvery as possible, they ended up using white face paint coated with aluminum dust. However, just nine days into filming, Ebsen began to experience cramps and shortness of breath and was eventually hospitalized for two weeks after his lungs failed. The part of the Tin Man then went to Jack Haley.