3. His costume featured a water-cooling system

Chewbacca‘s costume came with some difficulties. And Peter Mayhew was the one who had a hard time inside the furry outfit. At some point Mayhew would sweat in the costume and his face would detach from the mask creating a weird appearance of the character. Not mentioning how uncomfortable that was, and required him to put the costume on and off all the time.

Star Wars Episode III: Revenge of the Sith came with a revolutionary change in the design of Wookiee’s costume so when Mayhew reprised the role it was easier to wear it. The suit featured an overhaul to incorporate a specially made water-cooling system. And so, the problem was solved, Mayhew wasn’t getting overheated and he could wear the costume for long periods. No more sweating and no more on and off.