When Clint Eastwood cast Hilary Swank as Maggie Fitzgerald he liked her look but worried she was too slight to read as a professional pugilist on screen. To solve that problem Swank undertook an almost brutal regimen: five hours a day of ring work and weight training under professional trainer Grant L. Roberts, and a deliberate 19‑pound gain of muscle to sell the physical transformation. The dedication paid off on camera — but off camera she paid a price. Repeated blistering from the intense training led to a staphylococcus infection in her foot that the production notes describe as potentially life‑threatening. Swank concealed the infection from Eastwood while filming because she felt it would be out of character for Maggie to complain. The episode has been recounted repeatedly in production histories as a sobering reminder of how realistic physical preparation can cross into real medical danger on physically demanding shoots.
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