It's bad enough spending hours under hot studio lights with a heavy costume and makeup on, but we think finding out that you're allergic to the makeup and that it's slowly killing you is probably far worse. That was the issue facing original Tin Man actor Buddy Ebsen as he stepped in front of the camera.
Ebsen had been fine throughout rehearsals, and had recorded the movie's soundtrack, but when his makeup was applied to start filming, he was hospitalized with shortness of breath. The makeup was later revealed to contain aluminum dust! Ebsen was unable to continue and was replaced by Jack Haley. Makeup staff tried using aluminum paste instead of dust for his makeup but got some in his eye. He missed four days with an eye infection because of it. We think it would probably be better for everybody if people kept aluminum away from the ingredients list for makeup.