Ebsen, who would go on to become a television icon on The Beverly Hillbillies and Barnaby Jones, was originally cast as the Scarecrow in the 1939 film, with Ray Bolger in the role of the Tin Man. But after Bolger asked to swap parts because he had a personal love for the Scarecrow, Ebsen agreed, and the rest is history.
But 10 days into shooting, Ebsen was hospitalized due to damage he suffered from repeatedly inhaling the toxic aluminum powder, which made it extremely difficult for him to breathe.
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After the week and a half of shooting, Ebsen was unable to breathe, saying, "This was a most frightening moment ... My lungs felt as though someone had coated them with glue."
Ebsen never mentioned having any long-term effects from the exposure, and he died in 2003 at the age of 95.
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