When the Wizard of Oz began filming Buddy Ebsen (born Christian Ludolf Ebsen, Jr.) was cast as the Tin Man in the 1939 MGM movie.

Within days, Buddy was hospitalized as a result of inhaling aluminum powder used as part of his make-up. One chorus of "We're Off to See the Wizard" in the movie and soundtrack album retain Ebsen's original vocals as the Tin Man, recorded before he was forced to leave the production. Because of the prolonged hospitalization, he was replaced by Jack Haley (whose reformulated make-up used pre-mixed aluminium dust), and Ebsen's scenes were re-shot using Haley. Footage of Ebsen as the Tin Man still exists, and was included as an extra with the U.S. 50th anniversary video release of The Wizard of Oz (1939).

He was replaced by Jack Haley two weeks into the filming of the movie. Haley also played the role of Hickory.

Frank Morgan played Professor Marvel,the Wizard of Oz, the Cabbie, the Doorman, the Guard at the Castle, and the Doctor.

Bert Lahr played Zeke, and the Cowardly Lion.

More Info: en.wikipedia.org