RICHARD KIEL WHO WAS FAMOUS FOR PLAYING “JAWS” IN JAMES BOND FILMS, WAS ORIGINALLY CAST AS THE HULK, BUT WAS REPLACED AFTER PRODUCERS REALIZED HE DID NOT LOOK MUSCULAR OR TOWERING ENOUGH NEXT TO BILL BIXBY. BODYBUILDER LOU FERRIGNO THEN WON THE ROLE. ARNOLD SCHWARNZENEGGER WAS ALSO CONSIDERED, BUT TURNED DOWN BECAUSE HE WAS DEEMED TOO SHORT AT 6′ 2″ COMPARED TO FERRIGNO’S 6′ 5″ FRAME.
IN THE PILOT EPISODE, FERRIGNO PHYSICALLY FLIPPED A CAR UNASSISTED WHEN A STEEL CABLE USED FOR THE STUNT BROKE DURING A 4 AM SHOOT.
FERRIGNO WAS PARTIALLY DEAF AND TERRIFIED ON HIS FIRST BIG SET; BILL BIXBY SPEND HOURS OFF-CAMERA TEACHING HIM HOW TO EXPRESS EMOTION AND MOVE NATURALLY.