- Game of Thrones star Rory McCann was originally cast as Cassian’s friend, Brasso, in Andor Season 1.
- A severe on-set injury forced him to exit the role, leading to his replacement by actor Joplin Sibtain.
- The production used face-scanning technology to superimpose Sibtain’s face onto McCann’s initial performance.
- McCann is now confirmed to join the Star Wars universe as Baylan Skoll in the upcoming Ahsoka Season 2.
The Andor Role Fans Never Knew He Lost
Long before fans anticipated his debut in Ahsoka Season 2, Game of Thrones alum Rory McCann nearly made his Star Wars entrance in Andor. In a surprising revelation, it has come to light that McCann, famously known as The Hound, was the original actor cast to play Brasso, Cassian Andor’s loyal friend on the planet Ferrix.
However, a twist of fate prevented this version of the character from ever making it to screen. The role was ultimately portrayed by Joplin Sibtain, who delivered a memorable performance. The story of how this last-minute change occurred reveals the unpredictable nature of television production.
A Fateful Injury Halts Production
The secret behind the casting switch was revealed by Joplin Sibtain himself on the Star Wars Sessions podcast. According to Sibtain, who was initially brought on for a smaller part, McCann sustained a significant injury while filming.
“He just had a limp and he went to work,” Sibtain explained. After a medical scan, the situation proved dire. “The consultant said, ‘If you don’t have this operated on, you’re going to not be able to walk.’” Faced with a potentially debilitating injury, McCann had to step away from the project, leaving the production in a bind.
A High-Tech Solution Saves the Character
With McCann unable to continue, the production team turned to Sibtain, offering him the chance to read for the now-vacant role of Brasso. In a fascinating display of modern filmmaking magic, the solution involved more than just reshoots.
“They did a lot with The Hound’s face, they had to superimpose my face on [him],” Sibtain recalled. This use of face-scanning technology allowed the production to salvage initial footage and seamlessly integrate Sibtain into the role, a behind-the-scenes fact that has remained unknown to most viewers until now.
A Second Chance in a Galaxy Far, Far Away
While his debut was unexpectedly delayed, Rory McCann is finally getting his moment in the Star Wars galaxy. It was confirmed at Star Wars Celebration 2025 that he will take on the formidable role of Baylan Skoll in Ahsoka Season 2. He will be succeeding the late, great Ray Stevenson, who originated the character in the first season.
McCann’s casting has already earned high praise from his co-stars. Ivanna Sakhno, who plays Shin Hati, shared her excitement about working with him. “I get to see Rory nearly daily at the moment, and he has been amazing to work with,” she stated. “There couldn’t have been anyone better to take on this role.”
While Andor Season 2 has reportedly wrapped filming, fans can look forward to seeing McCann make his official Star Wars debut when Ahsoka Season 2 arrives, which is expected in 2026.
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