Kellan Lutz was praised and quizzed about his physical transformation for the role of Hercules and the length of time it took to transform himself when in fact Lutz was cast just 2 weeks before principal photography began. So the physique that you see in the film is more or less his regular physique. He credited his active life-style for allowing him to portray the role of Hercules at such a short notice because other actors would have required months to acquire the proper physique required for the character.
This is the second Greek Myth movie to star Kellen Lutz. The first was "Immortals" where Lutz portrayed Hercules' uncle, Poseidon.
When Kellan Lutz first landed the role, he said that physique-wise he wanted to get really big to portray Hercules. But director Renny Harlin told him not to get bigger, but to "get his abs to pop out more". So Kellan Lutz went with the look that his director had in mind.
Director Renny Harlin mandated that all the male actors shave their legs along with their torsos because the film was being shot natively in 3D and he said that hair stuck out when you shot with stereoscopic cameras.
Renny Harlin: Officer Linus, one of King Amphitryon's soldiers.
Kellan Lutz said that because he was shirtless through much of the movie, he could constantly do push-ups and ab-crunches on set before takes without fear of sweating into his costumes and staining them. He said it allowed him to look pumped on camera greatly enhancing his looks and he ended up doing more than a thousand push-ups and ab-crunches every day on set for the duration of the shoot.
Jukka Hilden from the Finnish stunt group The Dudesons played a character named Creon in the film, but the story arc he was in was cut from the film.
Kellan Lutz said that his co-star Scott Adkins had the body of a god and that his physique was so great that it looked green-screened, and "did not make his Hercules character look too well".
Renny Harlin said that he chose Scott Adkins for the role of King Amphitryon because of "his acting skills, his incredible physical ability and his incredible physique". He said that King Amphitryon "had to be the biggest badass the audience had ever seen and only Scott Adkins fit that bill".
Scott Adkins's character, King Amphitryon, is seen at two different ages in the film - younger and older - and Adkins created two different looks for the character. He said that he wanted to look extremely "lean and ripped" for the younger scenes - showing highly defined eight-pack abs in a shirtless scene - as compared to very "muscular and bulky" for the older scenes - where he just had to show his biceps in sleeveless costumes. He said for the younger scenes, he ate very carefully and trained a lot to achieve the ultra-cut look but for the older scenes, he trained just as hard but ate what he wanted because the focus was on size and not muscle definition and he did not have a shirtless scene anymore.
Not one Greek name amongst the actors in the entire cast list.
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