Tom Rhys Harries’ ‘Clayface’ Transformation Came With a Hidden Cost: He Built That Physique Around a Torn ACL
Hollywood loves a good body transformation. Actors bulk up, cut down and share the before-and-after photos, and audiences usually treat it as a badge of dedication. But the story behind one of this year’s most talked-about superhero physiques has a twist that most fans did not see coming.
Tom Rhys Harries stars as Matt Hagen in ‘Clayface,’ DC Studios’ R-rated body horror film that opened on October 23. The movie follows a Hollywood actor whose face is disfigured by a mob boss and who turns to an experimental procedure that transforms his body into shape-shifting clay. Harries, a 36-year-old Welsh actor, has worked on stage and screen for nearly 15 years, and this is his first comic book role.
Now GQ has taken a closer look at how Harries got ripped for the part, despite an injury that could have derailed the whole production. The magazine’s piece highlights that he built his physique with a torn ACL.
The photos that accompanied the story show Harries shirtless in a gym, with a lean, muscular build. A training video posted by his trainer, Dan Avasilcai, gave fans another look at the work behind the transformation. It shows Harries doing seated lat pulldowns, chin-ups, dumbbell hammer curls, EZ bar curls and cable flyes.
The post’s caption said DC was ready to unleash a new beast in its universe, with ‘Clayface’ arriving in cinemas that Friday. Harries is shown focusing on back, shoulders, arms and chest, which suits a character whose body is central to the story.
The most surprising part is the knee. Harries told Entertainment Weekly that he shot the entire film with a torn ACL, and that he had not told the stunt team or anyone on the production. He recalled one nighttime scene in which his character flees a premiere as his face begins to melt, saying he was hobbling and worried his knee might give out.
He described running around Liverpool at 1 a.m. or 2 a.m. trying to get away with it. Meanwhile, he is an active person who rides motorbikes, enjoys being in nature and used to surf and play football.
In a separate interview with Cultured, Harries explained the timing. He said he tore the ACL before filming started and was looking for a window to get it repaired. Then he booked ‘Clayface’ and realized he would not have time for surgery.
He noted that the procedure would have meant about two weeks of being unable to walk, followed by roughly two months of rehab before he could start running again. He later had surgery after finishing the risky action scenes.
Matt Hagen is an up-and-coming leading man whose good looks are slashed up by a local mafia boss. In desperation, he turns to an experimental treatment that backfires. The film leans into practical effects and body horror, and the physical demands on its lead were significant.
Harries has said his audition process with director James Watkins lasted months. James Gunn announced the casting in June 2025 after what he called a long and exhaustive search, adding that he and Matt Reeves were blown away by the actor.
The film opened at No. 1 at the box office with about $24 million domestically and an estimated $43 million worldwide. It earned an A- CinemaScore and strong audience scores, which has helped Harries step into the spotlight. Previously known for ‘White Lines’ and ‘The Gentlemen,’ he now leads a major DC release.
The physical transformation is part of that story, but it’s not the only part. His performance, and the effort behind it, has become a talking point.
Watch the first trailer for #Clayface. The new DC horror film is in theaters October 23. https://t.co/gqrrtJSou5
— Rotten Tomatoes 🍅 (@RottenTomatoes) April 22, 2026
It is worth noting that shooting with a torn ACL is not something to emulate. Harries himself has said he would not recommend it, and ACL injuries commonly take months to heal. His case shows how far some actors will go for a role, and also how risky it can be.
For fans, the takeaway is a little more complicated than a gym montage. The physique on screen was built with grit, careful training and a lot of quiet pain.
What impresses you most about Tom Rhys Harries’ ‘Clayface’ transformation?
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