Dwayne Johnson has opened up about the physical challenges of transforming into Maui for Disney’s upcoming live-action adaptation of Moana, revealing that a specially designed prosthetic suit was necessary after his dramatic body transformation for another film role.
The actor, who first voiced the demigod Maui in Disney’s 2016 animated hit Moana and returned for its 2024 sequel, is reprising the character in the live-action remake scheduled for release on July 10, 2026.
Speaking to E! News while promoting the film, Johnson explained that he had little time to alter his physique after completing work on The Smashing Machine, in which he portrayed former UFC fighter Mark Kerr.
“I went from Smashing Machine and I was 50 pounds heavier than I am now,” Johnson said. “I had no time to change my body.”
According to the actor, filmmakers briefly considered using his appearance from the sports drama, but ultimately decided it would not match audience expectations of Maui.
“We are the keepers of integrity, but also the fans are keepers of integrity,” Johnson said. “If I stepped on set looking like how I looked, they would have had a complete organ rejection.”
To solve the issue, Johnson worked with Academy Award-winning makeup artist Joel Harlow and a team of specialists to create a custom prosthetic bodysuit. The suit was designed to replicate Maui’s distinctive build and appearance while allowing visual effects artists to animate the character’s iconic tattoos.
“It worked out great because the tattoos are alive,” Johnson explained. “It was easier for the visual effects team and a better treat for audiences to see it on the suit.”
Despite praising the craftsmanship behind the costume, Johnson admitted that wearing it during filming was physically demanding.
“It was 40 pounds of suit that was hot as s***,” he said.
In addition to starring in the project, Johnson is also serving as a producer on the live-action remake, which is one of Disney’s most anticipated releases of 2026.
The film will reimagine the story of Moana and Maui for a new generation while bringing one of Disney’s most successful animated franchises to live-action audiences worldwide.
