The cast and crew bloopers, according to Mashable, include:
"-- Harrison Ford (as Han Solo) fluffs the line, "Great shot kid, that was one in a million" after Luke blows up the Death Star. Ford proceeds to eat his headset mic.
-- A squad of stormtroopers blows open a door on the Death Star, but a piece of the set about three feet high remains. The stormtroopers attempt to hop over the board, tumbling on to the other side as if emerging from a clown car.
-- Alec Guinness (Ben Kenobi) gets whacked in the face by Chewbacca's arm in the cockpit of the Millennium Falcon; Guinness proceeds to boggle his eyes and make faces at the camera.
-- Peter Cushing (Grand Moff Tarkin) imperiously insisting that Carrie Fisher (Princess Leia) "name the target" for the Death Star, then flubbing his line and collapsing into Fisher's arms.
-- Anthony Daniels (Threepio) struggling for several minutes to get to the top of a sand dune on Tatooine (ie. Tunisia), in a costume he could barely move in; Daniels falls over at the top.
-- Mark Hamill (Luke Skywalker) speaking a line cut from the final film, "Let's get some distance before that thing goes supernova," before pausing to ask George Lucas how he should pronounce "supernova."
-- An alien in the Mos Eisley Cantina repeatedly jabbing his middle digit into another alien's chest — until the digit bends back on itself. The alien looks at his deformed hand in horror. "