1. Delenn was originally going to be male.

This accounts for the hideous Minbari make up in the pilot. Male and female Minbari were supposed to be very hard to tell apart based on physical appearance alone, generally androgyonous in appearance and even movement. (That's one reason why the Minbari assassin was played by an actor with a relatively slight build.) Because Delenn would have been female for four out of five seasons JMS wanted to cast the actress from the beginning, rather than switch performers at the start of S2. (He was also concerned that Mira Furlan, who had auditioned for the pilot, might not be available when he needed her if he cast a male and signed him for the pilot and S1.) He wanted a continuity of performance and character, and planned to have Mira play the male Delenn, electronically altering her voice to avoid the obvious phoniness of dubbing a male voice over hers. (Which, again, would rob him of Mira's actual performance, substituting the voice actor's line readings for hers.)
But the electronic manipulation they tried also sounded phony. Since they hadn't found a suitable voice by the end of post production, and since they were expecting to start production on the first season almost immediately, JMS made the decision to drop the whole "male Delenn" thing (since he couldn't be sure they'd ever have a voice good enough to carry them through the whole first season.)
So they looped a single line referring to Delenn from "him" to "her" and used Mira's unalterned voice tracks - which a test audience had also responded to very favorably. Since the whole male Delenn storyline was being abandoned, there was no longer any reason to make the Minbar androgynous. They were now free to be as masculine and feminine as their Human counterparts and the makeups were altered to allow this. Thus we got to see a lot more of Mira's natural beauty, and we got a big, bearded and truly impressive Dukhat when the time came.

In the event, of course, Warner Bros. decided to put the series on hold until they had aired the pilot and reviewed the ratings, so it was nearly a year between the end of post on The Gathering and the start of shooting on "Infection". JMS used the time to refine a number of elements of the show, including the Minbari makeup.
Regards,
Joe
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