Buddy Ebsen’s brief involvement in The Wizard of Oz is well-known among classic film fans. Originally, he was slated to play the Scarecrow, but after the last-minute change, he took on the role of the Tin Man. The allergic reaction to the aluminum dust, which caused severe health issues, led to Ebsen’s departure from the production. It was said that his entire body reacted badly to the makeup, and he was replaced by Jack Haley, who famously wore a less harmful version of the makeup.
Ebsen, known for his dancing and acting talent, was cast to play the beloved metal man. To create the shiny silver look, makeup artists applied aluminum dust directly to his face and body—a practice that seemed harmless at the time but turned out to be incredibly dangerous.
After just nine days of filming, Ebsen began experiencing severe cramps, difficulty breathing, and chest pains. He was rushed to the hospital, where doctors found that he had suffered a serious reaction to inhaled aluminum particles. His lungs were so compromised that he had to spend days in a special oxygen tent. As Ebsen described the onset of symptoms in his autobiography:
“It was several days later when my cramps began. My first symptoms had been a noticeable shortness of breath. I would breathe and exhale and then get the panicky feeling I hadn't breathed at all. Then I would gasp for another quick breath with the same result. My fingers began to cramp, and then my toes. For a time I could control this unusual cramping by forcibly straightening out my fingers and toes.“One night in bed I woke up screaming. My arms were cramping from my fingers upward and curling simultaneously so that I could not use one arm to uncurl the other. My wife tried to pull my arm straight with some success, just as my toes began to curl; then my feet and legs bent backward at the knees. I panicked. What was happening to me? Next came the worst. The cramps in my arms advanced into my chest to the muscles that controlled my breathing. If this continued, I wouldn't even be able to take a breath. I was sure I was dying.”
While Ebsen was recovering, the studio quietly replaced him without notice. Jack Haley stepped into the role, and although the makeup formula was changed to a safer aluminum paste, he still developed a painful eye infection. Fortunately, Haley recovered and completed the film.
Ebsen’s scenes were removed, his name was taken off the credits, and he received no official recognition. Yet, his voice lived on. In one scene—when the characters sing “We’re Off to See the Wizard”— the studio kept his original vocal track. That cheerful voice? It’s Buddy Ebsen’s.
Despite the setback in The Wizard of Oz, Ebsen went on to have a successful career in both movies and television, most famously starring in The Beverly Hillbillies. It’s always interesting to learn how things might have been different if Ebsen had been able to complete his role in the iconic film.
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