The part of Chewbacca in the crackerjack space adventure movie Star Wars was originally offered to Danny DeVito. The suit and prosthetics were already made for him when he was forced to pull out of the project (due to a prior commitment to play Ulysses S. Grant in a musical version of the Battle of Gettysburg) and the costume was re-tailored for the replacement actor using bits of Lucas's shag-pile rug. If you look closely at an unretouched print you can clearly make out the alterations since the colors and naps do not match.