The Wizard of Oz
Ebsen replaced by Haley

The production faced the challenge of creating the Tin Man's costume. Several tests were done to find the right makeup and clothes for Ebsen. Ten days into the shoot, Ebsen suffered a toxic reaction after repeatedly inhaling the aluminum dust (which his daughter, Kiki Ebsen, has said the studio misrepresented as an "allergic reaction") in the aluminum powder makeup he wore, though he did recall taking a breath one night without suffering any immediate effects. He was hospitalized in critical condition and was subsequently forced to leave the project. In a later interview (included on the 2005 DVD release of The Wizard of Oz), he recalled that the studio heads appreciated the seriousness of his illness only after he was hospitalized. Filming halted while a replacement for him was sought.

No footage of Ebsen as the Tin Man has ever been released – only photos taken during filming and makeup tests. His replacement, Jack Haley, assumed Ebsen had been fired. The makeup used for Haley was quietly changed to an aluminum paste, with a layer of clown white greasepaint underneath, in order to protect his skin. Although it did not have the same dire effect on Haley, he did at one point suffer an eye infection from it. To keep down on production costs, Haley only rerecorded "If I Only Had a Heart" and solo lines during "If I Only Had the Nerve" and the scrapped song "The Jitterbug"; as such, Ebsen's voice can still be heard in the remaining songs featuring the Tin Man in group vocals.
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