Clint Eastwood wanted a believable fighter, and Hilary Swank delivered — at real personal cost. To bulk up and learn ringcraft for the role of Maggie Fitzgerald she trained nearly five hours a day in the ring and the weight room under trainer Grant L. Roberts, gaining 19 pounds of muscle. The relentless physical work produced severe blisters on her foot that developed into a potentially life‑threatening staphylococcus infection; Swank kept the illness from Eastwood, later saying she felt it would be out of character for Maggie to complain. Filmed in under 40 days in June–July 2004, the production’s compressed schedule and the actress’s extreme regimen highlight the hazardous side of method preparation — Swank recovered and went on to win the Best Actress Oscar, but the episode remains a stark example of how intensive physical transformations for roles can carry real medical danger.
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