Chewbacca's costume in the first Star Wars movie was actually woven from the hair of George Lucas' children in a budget minimising move. The children had to have their heads shaved several times in the run up to the production, and rumour has it the family dog was also roped in to the procedure when the children failed to produce enough hair in time for filming.
The production was famously short on funds, and a number of innovative cost-cutting measures were employed. Princess Leia's white gown doubled up as a bed sheet, while Alec Guinness reportedly donated a pair of false earlobes that he had worn as a prop in The Ladykillers, which were auctioned off to raise money. Previous tales of Harrison Ford demanding two chocolate biscuits per day when the budget would only stretch to one per cast member have consistently been denied.