A soundbite of Alec Guinness as Obi-Wan Kenobi was used in Star Wars: The Force Awakens. The crew took dialogue of Guinness saying the word “afraid” in the original Star Wars trilogy and then separated the middle sequence so he calls out “Rey” during her vision sequence.
2. Jeremy Bulloch did not read lines or screen test when he auditioned to play Boba Fett in Star Wars: The Empire Strikes Back and was only selected for the role because he fit inside the pre-made costume the best.
3. Director J.J. Abrams broke his back trying to help Harrison Ford off the floor after the actor fell and broke his leg on the set of Star Wars: The Force Awakens.
4. Michael Jackson attempted to persuade George Lucas into giving him the part of Jar Jar Binks in ‘Star Wars Episode 1: The Phantom Menace’, offering to play the role in full prosthetics.
5. The Starkiller Base was originally going to run on dark matter in Star Wars: the Force Awakens. Though the idea was changed in the final cut of the film, the initial concept saw the First Order utilising science they barely understood to power the weapon, which would’ve had the ability to rip holes in space and time.
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Academy Award-winning animator Phil Tippett admitted to tripping on LSD while working on the special effects of Star Wars Episode VI: Return of the Jedi.
7. A now non-canonical Star Wars expanded universe comic revealed that R5-D4, the droid Luke Skywalker almost purchased from the Jawas in Star Wars Episode IV: A New Hope before it self-destructed, was force sensitive and had a vision that the Empire would reclaim the Death Star plans and kill Leia if Luke did not purchase R2-D2.
8. Star Wars Episode VI: Return of the Jedi was initially going to feature giant aliens called Gorax who lived on the forest moon of Endor. This would’ve explained why the Ewoks were so adept at fighting the large weaponized vehicles of the Empire, as their primitive traps were originally designed to hunt Gorax.
9. George Lucas originally offered the Star Wars roles of Darth Vader and Ben Kenobi to Toshiro Mifune, who starred in many of Akira Kurosawa’s samurai movies. These films, specifically The Hidden Fortress, had a great influence on the Star Wars series.
10. For a short time during the development of the Star Wars Holiday Special, George Lucas contemplated marrying Han Solo to a Wookiee.
The unique sound of Kylo Ren’s force powers in Star Wars: The Force Awakens was created by altering the sound effect of a cat purring.
12. Mark Hamill was 63 years old while filming Star War: The Force Awakens, the same age as Sir Alec Guinness was while filming his scenes as Ben Kenobi in the original Star Wars film in 1977.
13. Harrison Ford was only at Star Wars auditions to read lines with other actors, not to actually audition for any part. He was eventually cast as Han Solo, however, because all of his line-readings were better than the actors who were actually auditioning for the role.
14. The double bladed lightsaber Darth Maul debuted in Star Wars Episode I: The Phantom Menace isn’t actually one complete unit, but two lightsabers welded together at the pommel. This explains why one blade still worked after it was sliced in half by Obi-Wan Kenobi.
15. Since George Lucas was originally planning on making 11 more Star Wars movies after the success of the first film, Boba Fett was created with the intention of becoming the central villain of Star Wars Episode VI: Return of the Jedi. However, shortly after production on the second film began, Lucas decided to end the series with Episode VI, and Fett’s role was heavily reduced.
Peter Mayhew, who played Chewbacca in the original Star Wars trilogy, had been wheelchair-bound since 2011 due to his old age and height. However, when he found out Chewbacca would appear in Star Wars: The Force Awakens, the actor underwent double knee surgery in 2013 in order to reprise the role.
17. 20th Century Fox was so worried about "Star Wars" being a failure in theaters that they paired booking it with the highly anticipated "The Other Side of Midnight", which became a box office flop.
18. George Lucas allowed the band members of 'N SYNC to make a cameo appearance in Star Wars Episode II: Attack of the Clones in order to appease his daughters. The footage was then cut out of the final version of the film.
19. David Prowse, the actor playing Darth Vader for the majority of the Star Wars films doesn't get invited to official Star Wars Conventions.
20. In the Star Wars Universe, the style of music being played by the Cantina Band is known as "Jizz"
George Takei once called for peace between Star Wars and Star Trek fans to unite against Twilight fans.
22. The death star trench sequence in Star Wars was inspired by the RAF dam busting missions during WW2.
23. All of the old buildings from Star Wars, such as Obi-Wan's house, Mos Espa, and Lars Homestead, are still intact and can be visited at Tunisia
24. Harrison Ford was paid $10000 for Star Wars: Episode IV – A New Hope.
25. After watching Star Wars, James Cameron decided to quit his job as a truck driver and entered into the film industry.