Originally posted by: Mugda
We know Aishwarya and Deepika are Bhansali's muses but they were not the original choice of his films. He always thought of Kareena first for his film but never got an opportunity to work with her.
For Khamoshi, he first wanted a teenage Kareena but couldn't manage to work with her. SLB then thought of Madhuri Dixit who also refused to work with a new director. He then cast Manisha.
For HDDCS, his first choice was again Kareena. Then Kajol and later Aishwarya.
For Devdas, he screen tested Kareena first. Then Aishwarya.
For Black, his first choice was Kareena but Amitabh refused to work with her.
For Bajirao Mastani, he wanted Aishwarya first but later officially signed Kareena. Still couldn't manage to work with her.
For Ram Leela, he cast Kareena but later signed Deepika.
Khamoshi
Sanjay Leela Bhansali started his career as assistant director for Parinda. Being on set and working with Madhuri Dixit in her prime he was besotted. He wrote Khamoshi for her. When she heard the script she found it too depressing (death of brother, traumatic childhood of character), plus she was already doing Prem Granth which dealt with rape and Yaraana which deals with domestic abuse around the same time.
He chased her for months but she was unconvinced. Next, I don't know which order it was in but he strongly considered Kareena Kapoor (of course adapting the age of the character to younger). He also spoke about wanting to cast Twinkle Khanna, with Dimple Kapadia to play her mother. But that didn't work out either. I'm not aware of any others that may have been approached. Finally he settled on Manisha Koirala.
Hum Dil De Chuke Sanam
He has said many times in public that he wrote the film and the character with Madhuri Dixit in mind. When he began the casting process, of course he wanted La Dixit, but he could not bare the humiliation of another rejection so he didn't approach her. (Later, after the film's release and success Madhuri has expressed regret at not being able to do the film and said she would have signed it if he'd approached her).
Kareena Kapoor was then signed up. A few years ago on Film Companion she revealed that she took a "signing amount". But then things just fell apart. I'm not sure why, can only speculate. I reckon she was faffing around with her date diary. She was juggling a potential big launch elsewhere.
He asked Kajol but she refused. He toyed with Manisha but wanted a fresh face. It was at the premiere of Raja Hindustani at the end of 1996 that he met Aishwarya Rai and he has said that he just knew she was his Nandini. And she was.
Devdas
Kareena Kapoor was so determined to get a role in the film that she turned up at his office with her mom Babita and sister Karisma in full Paro costume demanding a screen/look test. Of course Sanjay himself was dying to work with her, but for whatever reason it didn't work out. He also approached Kajol for the role of Paro but for reasons only Kajol will ever know, she refused.
Note: Aishwarya and SLB had a falling-out at one point after the awards season of 2000 (where HDDCS scooped all the awards). But they soon made up and Ash bagged the role, alongside Madhuri who finally fulfilled one of his longest ambitions.
Black
I do remember reading back in the day that Kareena Kapoor was supposed to do the film. But then he thought it would suit better to have her in Bajirao Mastani which he planned on shooting right after the release of Black. So Rani Mukerji got to celebrate Diwali early.
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