The making of Rang De Basanti, a film celebrated for its impact on Indian cinema, is a story filled with unexpected turns and casting choices that could have drastically altered its legacy. Initially conceived as a modest production, the film was set to feature Manoj Bajpayee in the lead role that eventually went to Aamir Khan.

Screenwriter Kamlesh Pandey recently revealed that Rang De Basanti spent six years in development, facing numerous rejections before Aamir Khan expressed interest. According to Pandey, Manoj Bajpayee was the original choice for the character of DJ/Chandrashekhar Azad. The film was envisioned as a small-budget project. However, Aamir Khan's enthusiasm for the script changed everything. His involvement not only lent credibility to the project but also attracted A.R. Rahman, who composed the film's memorable music. Subsequently, UTV, which had previously declined the film twice, quickly agreed to produce it.

The initial plan for a smaller film with Manoj Bajpayee faced challenges. Rakeysh Omprakash Mehra, the director, noted that the role "did not suit him" after further consideration. Before Aamir Khan's involvement, the film had been in development for seven years, with numerous actors considered for various roles. The director emphasized the importance of finding the right person for each role, which ultimately led to Aamir Khan's casting.

Interestingly, the casting process wasn't the only source of unusual stories surrounding the film's pre-production. Pandey shared that some producers misunderstood the film's premise, mistaking it for a remake of Sholay from Basanti's perspective. This led to inquiries about who would play Basanti, with one producer even accepting Esha Deol as a serious suggestion.

Randeep Hooda was also approached for a role but declined it because he didn't want to play second fiddle to Aamir Khan. Hooda later admitted that he regretted the decision. The cast ultimately included Siddharth, Soha Ali Khan, R. Madhavan, Kunal Kapoor, Sharman Joshi, Atul Kulkarni, Alice Patten, Anupam Kher, Waheeda Rehman, and Kirron Kher.

Manoj Bajpayee's near casting in Rang De Basanti adds another layer to the film's rich history. While it's fascinating to imagine Bajpayee in the role of DJ, Aamir Khan's portrayal undoubtedly resonated with audiences and contributed to the film's success. The film's journey from a small-budget concept to a major Bollywood production highlights the unpredictable nature of filmmaking and the impact that key decisions, such as casting, can have on a film's trajectory.