While George Lucas was filming in London, where additional casting took place, Kenny Baker, performing a musical comedy act with his acting partner Jack Purvis, learned that the movie crew was looking for a small person to fit inside a robot suit and maneuver it. Baker, who was three feet eight inches (1.12 meters and) tall, was cast immediately after meeting George Lucas. He said, "He saw me come in and said 'He'll do' because I was the smallest guy they'd seen up until then." He initially turned down the role three times, hesitant to appear in a movie where his face would not be shown, and hoping to continue the success of his comedy act, which had recently started to be televised.

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