Glen Powell Reveals He Blacked Out While Filming Chad Powers in Full Prosthetics: “I Couldn’t Breathe”

Actor Glen Powell, 36, is no stranger to physical challenges on set, but his latest revelation proves just how intense the filmmaking process can get. While promoting his upcoming role as Chad Powers, a fictional alter ego created by NFL star Eli Manning, Powell admitted that the heavy prosthetics required for the character caused him to black out during filming.

The Transformation Into Chad Powers

The Top Gun: Maverick and Anyone But You star is known for his versatile performances, but stepping into the shoes—literally—of Chad Powers required a next-level transformation. To pull off the look of Manning’s hilariously awkward character, Powell underwent hours of makeup and prosthetic applications that altered his face and body.

“By the time they were done, I didn’t even recognize myself,” Powell shared in a recent interview. “It was incredible… but also terrifying.”

The Scary On-Set Moment

The excitement of embodying Chad Powers quickly turned dangerous. Powell explained that the weight and restrictions of the prosthetics made it difficult to breathe and regulate his body temperature.

“At one point, I completely blacked out,” he admitted. “Everything went dark, and when I came to, the crew was fanning me and pulling pieces of the prosthetics off. It was definitely one of the scariest moments I’ve ever had on set.”

Fortunately, the actor was not seriously harmed, and production resumed after he recovered. Still, the incident highlighted the physical toll that transformative roles can take on performers.

Dedication to the Craft

Despite the frightening experience, Powell insisted that the effort was worth it to bring the larger-than-life character to the screen. “Acting is about disappearing into someone else, and with Chad Powers, that meant really going all in,” he said. “The prosthetics are a huge part of what makes him believable, so even though it was tough, I wouldn’t change a thing.”

Fans Can’t Wait to See the Role

Powell’s story has already sparked buzz online, with fans eager to see the actor’s full transformation. Social media users praised his dedication, calling him a “true chameleon” and “one of the hardest-working actors in Hollywood.” Others couldn’t help but joke about the irony of fainting while playing such a comedic character.

What’s Next for Powell

Beyond Chad Powers, Powell’s career shows no signs of slowing down. After a breakout year that included box office hits and award buzz, he has quickly become one of Hollywood’s most in-demand stars. Still, he acknowledges that this latest project will stand out as one of his most physically demanding roles.

“I’ll never forget what it took to become Chad Powers,” Powell said with a laugh. “Hopefully, audiences enjoy it enough to make all the blackouts worth it.”