In the wake of Robert Downey Jr.'s reported return to the Marvel Cinematic Universe, it's worth noting how seminal his previous character, Iron Man, was to the development of the franchise. One can argue that his career would not be where it is right now if not for Tony Stark.
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However, there is also an argument to be made that he too helped elevate the character of Iron Man to the level of relevance he has in the present-day Marvel mythos. Notably, the pair are connected by their own sordid pasts, with Robert Downey Jr. And his noted history of drug abuse becoming enough of a liability that he was paid a relatively smaller salary for the first Iron Man film. However, in its own way, this reflects the narrative of Tony Stark as a reckless rich boy with demons of his own, who was eventually able to redeem himself.
This begs the question: would Iron Man and the series built off its back be as successful as they are now with another actor? Despite the director, Jon Favreau, initially desiring an "up-and-comer" to play Tony Stark, a lot of performers who had established themselves at the time were considered to shoulder the debut of the Marvel Cinematic Universe. At various points in the pre-production stage, these actors were all names discussed as possible choices for the role.
5 Tom Cruise
Too Expensive
Tom Cruise has been an established actor since the 80s, with a penchant for action films such as Top Gun (1986) and the Mission Impossible franchise (1996-Present). His consistent bankability as a star would've likely placed plenty of eyes on the Iron Man film and its subsequent releases. However, this is also likely the reason he was not ultimately given the role of Tony Stark. Cruise's asking fee for the role was too high for what was, at the time, an untested superhero property.
Nonetheless, this previous consideration spurred debunked rumors from fans that he would appear as Superior Iron Man in Doctor Strange in the Multiverse of Madness (2022). While Cruise has not appeared in an MCU film to date, he has still shared the screen with a few of its actors, typically in the Mission Impossible series, where performers such as Jeremy Renner (Hawkeye), Hayley Atwell (Agent Peggy Carter), and Pom Klementieff (Mantis) have acted alongside him. Cruise was also cast in a film alongside Robert Downey Jr., with both appearing in Ben Stiller's controversial Hollywood satire film, Tropic Thunder (2008).
4 Jim Caviezel
Was Previously Cast In Another Marvel Film
Jim Caviezel is known as a controversial public figure with a similarly scrutinized filmography, starring in films such as Passion of the Christ (2004) and Sound of Freedom (2023). However, he was at one point a name considered for the titular role of Iron Man (2008). It is not widely known why he was considered, but he did fit the desired demographic for the role. Tony Stark is older than your average fledgling hero, so Caviziel, who was in his late 30s at the time of pre-production, would be an optimal choice in that regard.
The casting option may have also been influenced by the fact that Caviziel was previously cast for another Marvel role, outside the MCU, almost playing Cyclops in X-Men (2000). However, he dropped out before filming to instead star in the sci-fi thriller, Frequency (2000). Caviziel is not the only actor connected to X-Men to be given a shot at Tony Stark. Hugh Jackman was also reportedly offered the role, but declined, in part due to his commitments to the aforementioned X-Men series.
3 Timothy Olyphant
"The One Everyone Was Rooting For"
Timothy Olyphant is known for his leading roles on television, namely Deadwood (2004-2006) and Justified (2010-2015). He has also appeared in supporting roles in films such as Scream 2 (1997) and Once Upon A Time In Hollywood (2019). One Marvel insider who spoke to Time Magazine identified the "grimly conflicted turn" of his character, Sheriff Seth Bullock, in Deadwood as the reason he was a popular choice for the role during pre-production.
In an interview with The Playlist, Olyphant notes he was hesitant to get involved with bigger blockbuster films at first, but spoke positively of the auditioning process, as well as Jon Favreau. The two were also collaborating on The Mandalorian (2019-Present), which led Olyphant to remark that the director "doesn't owe [him] anything", noting that he gave him the role of Cobb Vanth.
2 Sam Rockwell
Favreau's Pick, Before Robert Downey Jr.
Sam Rockwell is an acclaimed actor who has starred in films such as Confessions of a Dangerous Mind (2002), Choke (2008), and Richard Jewell (2019). Initially, he was also a personal pick of Favreau's for the role of Tony Stark. However, this consideration was before Robert Downey Jr. Was considered as a possibility for the character.
Ultimately, Rockwell did actually end up in the MCU, appearing in Iron Man 2 (2010) as Justin Hammer, a weapons developer who serves as a rival to Tony Stark. Rockwell also reprised this role in the MCU short film All Hail the King (2014) as well as in season 2 of the ongoing series, What If...? (2021-Present).
1 Clive Owen
Feige's Pick
One reason why Robert Downey Jr. Got the role of Tony Stark, was because Kevin Feige's earlier pick passed on the role. This pick was English actor Clive Owen, star of films such as Closer (2004) and Sin City (2005). The President of Marvel Studios remarked on Owen's refusal of the role in a commencement speech for USC's 2023 graduation ceremony.
Feige stated that the experience taught him people shouldn't be discouraged when faced with setbacks, because their first choice may not necessarily be the best choice. Although Robert Downey Jr was considered a liability at first, it's clear that casting him did ultimately bring success to the greater Marvel Cinematic Universe.
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