How Every Actor in the Wizard of Oz Suffered Behind the Scenes

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Ignacio Weil

Entertainment - September 16th 2025, 18:30 GMT+2

The Winged Monkeys – Aerial Antics Gone Awry

Flying might look magical on screen, but for the actors playing the Winged Monkeys, it was more nightmare than fantasy. Heavy, unwieldy wings combined with faulty rigging led to several dangerous falls, leaving performers bruised and shaken. The masks and makeup caused itching, rashes, and general discomfort that lasted long after the cameras stopped rolling. Hours of hanging in harnesses strained muscles and joints, making every take a physical trial. Safety precautions were minimal, and each stunt felt like a gamble. For these actors, soaring across the Emerald City was as terrifying as it was unforgettable. | © Metro-Goldwyn-Mayer Studios Inc.

Cropped Buddy Ebsen — Buddy Ebsen – The Tin Man Who Almost Couldn’t Breathe

The story of the original Tin Man is a cautionary tale of early Hollywood recklessness. Buddy Ebsen inhaled aluminum dust from the makeup, which nearly killed him and led to hospitalization. His lungs were inflamed, and the doctors had to intervene before permanent damage occurred. MGM had to recast him, leaving Ebsen watching from the sidelines as his role was taken over. The trauma from this experience left lasting anxiety about on-set safety. What was meant to be a magical performance became a literal battle for survival. It’s a stark reminder that movie magic often came at a real cost. | © Metro-Goldwyn-Mayer Studios Inc.

Cropped Jack Haley — Jack Haley – Stepping into the Tin Shoes

Replacing Buddy Ebsen was no small task, and Jack Haley quickly discovered the role came with its own dangers. The reworked makeup might have been safer, but it still caused Haley an eye infection that forced breaks during filming. The metallic suit restricted his movement, turning even walking into a challenge, and heat from the studio lights made hours unbearable. Makeup and costume changes were exhausting, leaving Haley drained by the end of the day. Stiff movements were necessary to avoid accidents, and every scene demanded patience and perseverance. Behind the shiny facade, the Tin Man’s actor endured a constant grind. | © Metro-Goldwyn-Mayer Studios Inc.

Cropped Bert Lahr — Bert Lahr – Roaring Through the Heat

Being the Cowardly Lion meant carrying nearly 100 pounds of real lion fur over a long, hot shooting day. The suit trapped heat and sweat, making dehydration a constant threat, and Lahr often had to drink his meals through a straw just to survive. Studio lights only worsened the situation, creating a sauna-like environment. Movement was awkward and exhausting, yet the actor had to project energy and emotion through the heavy costume. Bruises and sore muscles were an everyday reality, hidden beneath the cheerful roar audiences adored. It’s hard to imagine a performance so iconic coming from such physically punishing conditions. | © Metro-Goldwyn-Mayer Studios Inc.

Cropped Ray Bolger — Ray Bolger – Stretching Every Straw Fiber

The Scarecrow’s charm came at a painful price. Ray Bolger’s latex mask, glued directly to his face for hours, caused irritation and left permanent scars. Removing it each day was a slow, uncomfortable process, and the glue left marks that never fully faded. The costume, padded and stiff, restricted movement, making dancing and bending difficult. Sweat and stage lights made each day sticky and exhausting. Bolger endured these hardships while still delivering an energetic, endearing performance that belied the pain beneath. Behind the straw-stuffed facade was a relentless test of endurance. | © Metro-Goldwyn-Mayer Studios Inc.

Cropped Margaret Hamilton — Margaret Hamilton – The Witch Who Burned (Literally)

Filming the Wicked Witch of the West’s dramatic entrances wasn’t just scary – it was downright hazardous. During the fire trap scene, a mistimed pyrotechnic caused serious burns to Margaret Hamilton’s face and hands. The green makeup that made her iconic also irritated her skin, turning long days on set into a trial of patience and resilience. Despite these challenges, Hamilton delivered every sinister laugh and menacing glare with precision. Behind the cackle was a mix of professionalism, bravery, and a few singed eyebrows. Hollywood magic has its perils, and Hamilton faced them head-on. | © Metro-Goldwyn-Mayer Studios Inc.

Betty Danko wizard of oz — Betty Danko – The Witch’s Daredevil Double

Few people realized that many of the Wicked Witch’s most dangerous stunts were performed by her double, Betty Danko. Harnessed into flying rigs, navigating narrow platforms, and dealing with real fire, Danko faced serious risk every day. She had to move with agility while staying completely in character, which often meant performing under extreme pressure. The stunts demanded endurance, timing, and nerves of steel. Without her behind-the-scenes heroics, the Witch’s most memorable moments might never have thrilled audiences. Danko proved that heroism sometimes happens out of the spotlight. | © Metro-Goldwyn-Mayer Studios Inc.

Cropped Terry the Dog — Terry the Dog – A Paw-sitive Recovery

Terry, the Cairn Terrier who portrayed Toto, was more than just a canine companion on set; she was a true professional. During filming, an unfortunate accident occurred when a Winkie guard accidentally stepped on her paw, leading to a sprain. This injury required her to take a brief hiatus from shooting to recover. Despite the setback, Terry's dedication remained unwavering. She returned to the set after a two-week recovery period, continuing to deliver her scenes with the same enthusiasm and charm that made her a beloved character. Her resilience and commitment to her role were truly remarkable, showcasing that even in the world of cinema, animals can be just as dedicated as their human counterparts. | © Metro-Goldwyn-Mayer Studios Inc.

Cropped Judy Garland — Judy Garland – Behind the Ruby Slippers

Judy Garland's portrayal of Dorothy in *The Wizard of Oz* is iconic, but the journey to that role was fraught with challenges. At just 16 years old, she was subjected to extreme pressures by MGM studios. Executives administered amphetamines to keep her energetic and thin, and barbiturates to help her sleep, leading to a cycle of substance abuse that began during production. Garland's struggles weren't limited to physical health; she also faced emotional and psychological tolls. Reports from her ex-husband, Sid Luft, allege that Garland was sexually harassed by some of the actors portraying the Munchkins, adding to the distress she experienced on set. These experiences contributed to a tumultuous life marked by addiction and personal hardships, culminating in her tragic death at 47. | © Metro-Goldwyn-Mayer Studios Inc.

Cropped Toxic Snow — Everyone on Set – The Toxic Snow of Oz

The “snow” in the poppy field looked magical, but behind the camera, it was anything but. The white flakes that fell during filming were made of asbestos, a material later known to be extremely dangerous. Cast and crew alike breathed in the particles for hours while working in the heat of studio lights, creating a toxic cocktail no one could avoid. Actors coughed, sets were slippery, and crew members worried about long-term effects – all in the name of cinematic wonder. It’s a grim reminder that the magic of classic films sometimes came at real-world risks. Even a seemingly innocent snowfall could be hazardous when Hollywood was involved. | © Metro-Goldwyn-Mayer Studios Inc.

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When The Wizard of Oz premiered in 1939, it dazzled audiences with its vibrant Technicolor, unforgettable songs, and timeless characters. But behind the magic of the Emerald City, the cast endured grueling hardships that few fans knew about at the time. From dangerous makeup that caused serious health issues to physically demanding costumes and punishing work conditions, the actors paid a steep price to bring the classic film to life. In this article, we’ll uncover the hidden struggles faced by Judy Garland, the Tin Man, the Cowardly Lion, the Wicked Witch, and others who made The Wizard of Oz the legendary film it is today.