
It’s now been 40 years since “Alien” hit theaters and kicked off one of the most popular sci-fi movie franchises of all time. From the unexpected downsides of the Xenomorph costume to the Hollywood stars who almost appeared in the movie, here are 15 things you might not have known about the making of “Alien.”
1. The original screenplay featured the title “Star Beast,” but writer Dan O’Bannon decided “Alien” was more effective and direct.
2. Harrison Ford was originally offered the role of Captain Dallas but turned down the part.

3. According to director Ridley Scott, Meryl Streep was also strongly considered for the role of Ripley and may well have been cast if not for the sudden death of her partner, John Cazale.
4. Jon Finch was originally cast as Kane, but had to drop out on the first day of filming due to complications from diabetes.

5. H.R. Giger‘s original Xenomorph design included visible eyes, but this was removed in order to give the creature a more inhuman appearance. Scott also purposely avoided filming the Xenomorph straight-on, in order to emphasize its terrifying nature.
6. In order to create the set for the Xenomorph egg chamber, the crew borrowed a set of laser lights from The Who, who were rehearsing on a nearby sound stage.

7. The facehugger was originally meant to be painted green, but O’Bannon liked the stark, humanoid look of the unpainted puppet and chose to leave it as-is.
8. Many of the gore effects were achieved by using raw animal parts, including cattle hearts and sheep intestines. That helped fuel the actors’ genuine reaction of fear during the infamous chestburster scene.

9. The names for the Nostromo crew members were chosen in part because they’re gender-neutral. None of the characters have a specified gender in the screenplay.
10. The crew had to design a special swing for actor Bolaji Badejo because his Xenomorph costume made it impossible to sit down in between takes.

11. One of the early shots of the interior of the Nostromo features a coffee grinder hanging on a wall. That prop was later used to create the Mr. Fusion engine in “Back to the Future.”
12. Most of the creatures models had to be repainted every single day due to the corrosive effects of the slime used to coat them.
13. The Space Jockey prop measured a full 26 feet tall. Unfortunately, it was accidentally destroyed when a discarded cigarette set it on fire.

14. One of the many deleted scenes from “Alien” features Ripley and Dallas having casual sex as a way of relieving the boredom of their journey. Scott eventually re-purposed that idea for 2012’s “Prometheus.”
15. The Xenomorph only appears on-screen for a total of four minutes in the theatrical cut.































It’s been a mind-boggling 35 years since “
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2. Speaking of Yoda, the aged Jedi Master wasn’t originally meant to be included in the film. Lucas added the Luke/Yoda reunion after speaking with a child psychologist and being told that younger viewers needed hard confirmation that Darth Vader is Luke’s father in order to accept the twist.
3. Lucas clashed with writer
5. The costume designers tried — and failed — to design Ewok masks that featured blinking eyes. Lucas later digitally added blinking eyes for the 2011 Blu-ray release.
6. The word “Ewok” is never actually spoken in the film. Also not spoken in the film? Palpatine. The big bad is never referred to by his actual name, just “The Emperor.”
7. Originally, Luke’s lightsaber blade was colored blue in the film, and appeared that way in early footage and on the “Revenge of the Jedi” teaser poster. Lucas changed the color to green in order to make it clearer that Luke had built a new saber and not recovered the one he lost in Cloud City.
8. Lando’s co-pilot, Nien Nunb, isn’t speaking alien gibberish, but an actual Kenyan dialect known as Haya. His lines were dubbed by a Kenyan student named Kipsang Rotich.
9. “Return of the Jedi” is the only Star Wars movie in which Darth Vader appears but doesn’t Force-choke another character.
11. When filming his Endor scenes at the Redwood National Forest in California, Chewbacca actor Peter Mayhew had to be escorted by crew members so locals wouldn’t mistake him for Bigfoot.
13. Han Solo’s fate at the end of “Empire Strikes Back” was left ambiguous in case Harrison Ford elected not to return for the sequel. Ford also campaigned for Lucas to kill off his character in “Return of the Jedi,” though he wound up having to wait until 2015’s “Force Awakens” to get his wish.
14. Four different actors were required to bring Vader to life in this sequel.
16. Lucas has admitted to regretting Boba Fett’s infamous death scene after learning just how popular the bounty hunter had become with fans. Lucas even considered adding a scene on the 2004 DVD release that would have shown Fett escaping from the Sarlacc.
17. When it came time to expand the musical sequence in Jabba’s palace, actress Femi Taylor was called on to reprise the role of Twi’lek dancer, Oola. She was the only Original Trilogy actor to return for the Special Editions.