Margaret Hamilton was left with burns on The Wizard of Oz

1939 classic The Wizard of Oz famously features Margaret Hamilton’s Wicked Witch of the West disappearing in a small explosion. While SFX would probably be used today, back then they simply set off a real pyrotechnic on set. On one take it went off too soon, leaving Hamilton with second and third degree burns. The actress came close to suing the studio over the accident.

Daniel Craig had two teeth knocked out shooting Casino Royale

Daniel Craig never made any secret of how physically gruelling he found the James Bond movies, and it’s no wonder considering what happened on his first film in the role. Whilst shooting a fight scene in Madagascar for 2006’s Casino Royale, two of Craig’s front teeth were knocked out. The actor’s dentist was flown in from London to fix him up again.

Tom Cruise broke his ankle jumping between buildings on Mission: Impossible – Fallout

Sometimes, Tom Cruise’s insistence on doing his own stunts has consequences. Whilst performing a comparatively simple jump between two buildings on 2018’s Mission: Impossible – Fallout, Cruise misjudged the landing and wound up shattering his ankle. Production on the action sequel had to be paused for nine weeks to give the leading man time to recover.

Audrey Hepburn suffered a miscarriage after being thrown from a horse on The Unforgiven

Whilst shooting 1960 western The Unforgiven, Audrey Hepburn was thrown from a horse and suffered a broken back. This injury healed, but there was another, more terrible consequence: the actress had been pregnant, and suffered a miscarriage. This would be the first of five miscarriages Hepburn would suffer throughout her life, although she would also give birth to two healthy children.

Linda Blair suffered a spinal fracture on The Exorcist

As gruelling as 1973’s The Exorcist is for audiences, making the film was also a tough experience for the cast, not least the young Linda Blair as the possessed child Regan. For a levitation scene, Blair was fitted into a mechanical device which malfunctioned on one take, throwing her so violently her spine was fractured. This injury ultimately led to Blair developing scoliosis.

Vincent D’Onofrio needed knee surgery after a fall on the set of Full Metal Jacket

For the role of trainee Marine ‘Gomer Pyle’ in the 1987 Vietnam War drama Full Metal Jacket, actor Vincent D’Onofrio piled on 70 pounds in weight. This made the film’s more physical scenes hard work for the actor, and whilst shooting the obstacle course sequence, D’Onofrio badly twisted one of his knees. The injury was so bad, D’Onofrio later had to undergo surgery.

PJ Soles suffered a ruptured eardrum from a water cannon on Carrie

In the notoriously nightmarish finale of 1976 horror movie Carrie, PJ Soles’ character Norma appears to get off light, being seemingly knocked out but not necessarily killed by a high-pressure hose. However, Soles actually suffered a serious injury shooting the scene, as the water pressure was so high, her eardrum burst. Happily, the actress fully recovered and can still hear through that ear today.

Sandahl Bergman’s fingertip was cut off on Conan the Barbarian

Shooting swordfights can be a hazardous business, as Sandahl Bergman found out the hard way on 1982’s Conan the Barbarian. Whilst shooting one such scene for the 1982 fantasy adventure, the actress’s fingertip was accidentally cut off. Happily, the severed digit was successfully re-attached after Bergman was rushed to hospital.

A real bomb went off in Harold Lloyd’s hand on Haunted Spooks (1920)

One of cinema’s original daredevils, Harold Lloyd, came frightening close to death whilst shooting his 1920 film Haunted Spooks. Posing for a picture, Lloyd picked up a bomb and lit the fuse, believing it to be a prop. Shockingly, the device was real and detonated in his hand. Lloyd was temporarily blinded, and permanently lost the thumb and forefinger of his right hand.

Sylvester Stallone’s neck was almost broken by Steve Austin on The Expendables

Sylvester Stallone may have been 64 when he shot 2010’s The Expendables, but he was still determined to give the action film his all. Whilst shooting a fight scene with actor/wrestler Steve Austin, the two musclemen overdid it a bit, leaving Stallone with a serious neck injury. Rushed into surgery, Stallone had to have a metal plate put in his neck.