Peter Mayhew, at 7-foot-2, worked as a porter in a London hospital before playing Chewbacca the Wookiee.
Show-biz vet Kenny Baker, the actor inside R2-D2, is only 3-foot-8.
Carrie Fisher, then 19, was asked to lose 10 pounds for the role of Princess Leia and tape her breasts so she didn't jiggle.
Mark Hamill, who failed to make the cut at an "American Graffiti" audition, went to a dual casting for "Carrie" and "Star Wars" and thought George Lucas was Brian de Palma's gofer.
David Prowse, who provided the body of Darth Vader, is a retired undefeated heavyweight boxing champion.
The daily production cost for "Star Wars" ran roughly $100,000.
Alec Guinness received two profit points, each worth about $300,000 at the time, for his work as Obi-Wan Kenobi. Mark Hamill, Carrie Fisher and Harrison Ford divided 2 percent of the profits among themselves.
For a long time, James Earl Jones, who refused screen credit, had fun denying he was the voice of Darth Vader, but the $10,000 role led to much work as a voice of authority.
Filmmaker Lucas hated President Ronald Reagan's using "Star Wars" as the name of the Strategic Defense Initiative weapons system, even suing fruitlessly to stop it.
"Star Wars" was shot in Tozeur, Tunisia; Nevada's Death Valley; Tikal National Park, Guatemala; Elstree Studios outside London; and Shepperton Studio in Middlesex, England.
SOURCES: "George Lucas, The Creative Impulse" by Charles Champlin; "Skywalking, The Life and Films of George Lucas" by Dale Pollock