Han Solo was supposed to die in Return of the Jedi but George Lucas was afraid it would affect toy sales so he killed off some Ewoks instead
Al Pachino was offered the Han Solo role, turning it down because "The script was too confusing".
George Lucas originally envisioned the planet Tatooine in Star Wars to be a jungle planet, but the idea of having to film in a jungle made him feel "itchy," so he decided to make it a desert planet instead.
20th Century Fox was convinced that Star Wars was going to flop so they agreed to let George Lucas keep licensing and merchandising rights instead of a 500k director's fee.
Han Solo was frozen in The Empire Strikes Back because Harrison Ford had only signed on for two films and George Lucas wasn't sure he'd return
Miss Piggy was originally voiced by the same person as Yoda
Star Wars was one of the first films to do away with opening credits. George Lucas was fined $250,000 by the Directors Guild of America for not crediting himself... so he resigned
Chewbacca's voice was created with a combination of vocalizations of bears, walruses, badgers, and the howls of sick animals.
Darth Vader's lines were recorded in 2.5 hours and James Earl Jones was paid just $7,500