As Favreau tells it, Rockwell was on his very short list of actors he wanted to play Tony Stark/Iron Man. Says Favs, “There was some things he would bring to the role that would have been great. Sam is very charismatic and when I was looking at the character there was a list and he had a spot on it, which might have surprised some people.”
Of course also on that list was Robert Downey, Jr. who probably won out because of simple name recognition. But it just goes to show that there are different types of actors out there for superhero roles besides the same few guys over and over again. Part of IRON MAN’s manic success was the casting of Downey which, at the time, was an unexpected choice. I’m not sure Rockwell will have a chance to play his own superhero but I’d love to see another director give him a shot.