The Role: Mr Freeze
Who Was Cast Instead: Arnold Schwarzenegger
As further evidence that there was something fundamentally wrong with Joel Schumacher's tenure as Batman director, Hogan was third choice to portray Mr. Freeze (behind Arnold Schwarzenegger and runner-up Sylvester Stallone). He needed someone hefty because the costume weighed a frankly ridiculous 75 lbs.
Mercifully, Schwarzenegger passed the audition to temporarily flush his career and legacy as an actor down the drain with some of the sickest puns ever committed to screen.
While Arnie wasn't exactly great (mostly thanks to the material), he at least sold the emotional undercurrent of the pantomime character. Hulk would haven been an unmitigated, monstrous disaster with no secondary depths and even more misplaced joy in the puns.