That two-minute plane scene cost $90 million and a year-long production shutdown.Cast Away started filming in January 1999 and stopped two months later. Tom Hanks needed to lose 50 pounds and grow out his hair to look like someone stranded on a Pacific island for four years. He'd already gained 50 pounds before shooting to play a soft, comfortable FedEx executive. No CGI, no prosthetics. The transformation had to be real, and it took a full year.Director Robert Zemeckis didn't sit around waiting