The casting of Bruce Willis in the iconic 1988 film "Die Hard" was far from straightforward. A-list actors like Arnold Schwarzenegger, Clint Eastwood, and Richard Gere all declined the role of John McClane. Willis wasn't even initially considered. According to Nick de Semlyen's book, "The Last Action Heroes," it was Willis's agent, Arnold Rifkin, who seized the opportunity, negotiating a substantial $5 million fee, capitalizing on the studio's struggle to find their lead.

Producer Larry Gordon admitted their casting difficulties, revealing that despite a strong script, they were unable to secure a suitable actor for the part. Rifkin's ultimatum to the "Die Hard" team ultimately sealed the deal for Willis.

Interestingly, Willis had initially turned down the role due to his commitment to the television series "Moonlighting." However, co-star Cybill Shepherd's pregnancy created an unexpected opening in his schedule, allowing him to reconsider. Despite skepticism from "Moonlighting" creator Glenn Gordon Caron, who considered it a "Schwarzenegger movie," Willis accepted the $5 million offer.

The first day of filming involved a risky stunt that nearly went disastrously wrong. Willis, coated in a fire-retardant gel, jumped from a five-story parking garage onto an airbag. Simultaneously detonated gasoline bags propelled him dangerously close to the airbag's edge, prompting the crew to rush to his aid. Willis initially mistook their concern for praise, unaware of how close he came to missing the airbag entirely. According to de Semlyen, the decision to film this scene early was a strategic move, allowing for recasting if the stunt proved fatal.

While Willis reacted with laughter, his then-girlfriend Demi Moore was understandably terrified. Moore later recounted the incident, highlighting the near-fatal nature of the stunt and Willis's nonchalant response. Director John McTiernan, however, downplayed the danger, emphasizing the importance of safety on set while acknowledging the stunt's role in helping Willis grasp the intensity of the scene.

"Die Hard" became the highest-grossing action film of 1988, launching Willis's successful career. Sadly, in 2022, Willis retired from acting following an aphasia diagnosis, later confirmed as frontotemporal dementia.