The 1939 film The Wizard of Oz remains one of the most beloved movies of all time, but behind its enchanting songs and magical sets, the actors who brought it to life faced real challenges that left some of them with lasting physical and emotional scars. Buddy Ebsen, Ray Bolger, Margaret Hamilton, and Judy Garland—all iconic actors from the film—endured on-set injuries and long-term health issues that would affect them for the rest of their lives. Here's how their work on The Wizard of Oz resulted in lifelong disabilities.

1. Buddy Ebsen – The Original Tin Man

Buddy Ebsen, best known later in life for his role as Jed Clampett in The Beverly Hillbillies, was originally cast as the Tin Man in The Wizard of Oz. However, Ebsen never made it to the final cut of the film, as the aluminum dust used in his makeup caused a severe allergic reaction. In the 1930s, film makeup often contained toxic ingredients, and Ebsen’s makeup included pure aluminum powder that he inhaled during filming.

The reaction was so severe that Ebsen’s lungs became coated with aluminum dust, causing breathing problems, painful muscle cramps, and near-fatal hospitalization. He spent two weeks in an oxygen tent and was unable to continue working on the film. Although he survived, his lungs were permanently damaged, and Ebsen lived with respiratory issues for the rest of his life.

2. Ray Bolger – The Scarecrow’s Burden

Ray Bolger’s performance as the Scarecrow is unforgettable, with his floppy dance movements and charming personality. However, the physical demands of the role, along with the heavy, restrictive costume, took a serious toll on Bolger’s body. The Scarecrow costume was made of burlap, and the mask was glued directly onto Bolger’s face, which caused irritation and discomfort during filming.

Worse, Bolger's costume was so tight and stiff that it restricted his movement and breathing. As a result, Bolger was left with permanent lines and indentations on his face where the makeup had been applied, and the constant physical strain of his performance led to chronic back problems. Despite these injuries, Bolger continued his acting career, but he always carried the physical reminders of his time as the Scarecrow.

3. Margaret Hamilton – The Wicked Witch’s Burns

Margaret Hamilton's portrayal of the Wicked Witch of the West is one of the most iconic villain performances in cinema history, but it came at a terrible cost. During one of the most memorable scenes, where the Wicked Witch disappears in a cloud of smoke after confronting Dorothy in Munchkinland, Hamilton suffered severe burns.

The trapdoor used in the scene malfunctioned, and Hamilton was caught in the flames from the special effects explosion. Her face and hands were badly burned, leaving her with second- and third-degree burns. Hamilton endured weeks of recovery and permanent scars from the accident. She was understandably hesitant to return to work and refused to perform any stunts involving fire for the remainder of her career.

4. Judy Garland – The Emotional Toll on Dorothy

Judy Garland’s performance as Dorothy in The Wizard of Oz made her a Hollywood legend, but behind her wide-eyed innocence and powerful voice was a life of pain and struggle. At just 16 years old, Garland was subjected to the pressures of fame, an abusive studio system, and a rigorous filming schedule. MGM, the studio behind the film, imposed harsh demands on her, controlling everything from her appearance to her weight.

Garland was given diet pills and amphetamines to control her weight and keep up her energy during the grueling production schedule. These practices led to a lifelong struggle with addiction and emotional instability. The stress of maintaining her Hollywood image, coupled with the constant scrutiny of her appearance, deeply affected Garland’s mental health. She battled depression, anxiety, and substance abuse throughout her life, which ultimately contributed to her tragic death at age 47.

While The Wizard of Oz remains a classic, the stories of the actors who brought its characters to life remind us of the darker side of Hollywood’s golden age. Buddy Ebsen, Ray Bolger, Margaret Hamilton, and Judy Garland all paid a high price for their roles, facing lifelong disabilities and health issues. Their performances may have become timeless, but the toll it took on their lives is a haunting reminder of the physical and emotional challenges actors can endure behind the scenes.