1

It took 3 actors to portray Darth Vader. James Earl Jones did the voice, Sebastian Shaw was his face, and David Prowse was his body.

2

Perhaps the silliest sounding role was Han Solo who was meant to be a green skinned monster who had a set of gills and no nose.

3

Also, Luke and his family were originally imagined as dwarves.

4

Originally, the force was going to be some sort of "Galactic Holy Grail" named the Kyber Crystal.

5

Of the asteroids in Empire Strikes Back, one is a shoe and another is actually a potato.

6

Steven Spielberg was Lucas's first choice to direct Return of the Jedi but he was part of the Director's Guild which Lucas had left on bad terms so Steven was forbidden from taking the role.

7

Peter Mayhew, the actor who played Chewbacca, was 7'2" 2.2 meters

8

George Lucas was famous for using words from non-English languages to name things. Yoda means "warrior" in Sanskrit and Darth Vader is named after the Dutch word for "father".

9

The word Ewok isn't mentioned in the film at all.

10

The Ewok were name after the Miwok, a Native American tribe indigenous to the location where the Endor scenes were filmed.

11

R2-D2 is named after a piece of film editor's jargon. It means "reel 2, dialog 2".

12

Al Pacino and Christopher Walken were also considered for the role of Han Solo.

13

After discovering that the 20th Century Fox special effects department was shutdown just prior to filming, George started his own company known as Industrial Light And Magic.

14

It's original title was "Adventures of Luke Starkiller as taken from the Journal of the Whills, Saga I: The Star Wars". It was eventually shortened.

15

Mark Hamill, the actor who played Luke Skywalker, damaged his face in a car accident following primary shooting which made reshoots impossible.

16

It took up to 10 puppeteers using both hands to operate Jabba the Hut

17

The character of Han Solo was based on Lucas's friend Francis Ford Coppola, the director of The Godfather.

18

The Millennium Falcon was inspired by the shape of a hamburger with and olive in its side.

19

Chewbacca was based on George Lucas' dog, Indiana. His dog is also the inspiration for the name Indiana Jones.

20

John Williams won an Oscar for the Star Wars soundtrack. The American Film Institute later named it the greatest film score of all time.

21

Every Star Wars movie in the United States has been released in May, one week after George Lucas's birthday

22

George Lucas was diagnosed with hypertension and exhaustion as a result of filming Star Wars

23

The sound of Darth Vader's labored breathing was achieved using a scuba regulator.

24

Frank Oz, the actor who voiced Yoda, also voiced Miss Piggy on the Muppets

25

Star Wars is the most successful movie related toy line ever with 250 million action figures sold between 1978 and 1986