‘Holes’ Star Khleo Thomas Shares His Worst Moment Making the 2003 Film (Exclusive)

Holes was a challenging film to make. 

Between the heat and desert conditions, Khleo Thomas, who played Zero in the 2003 hit film based on the 1998 novel of the same name, faced some challenges making the movie. However, by far his worst experience on set was getting “heat rash,” he tells PEOPLE. 

“I remember it still today. I don’t know what happened. We had been in the desert a month by that time, and all of a sudden, maybe they changed the material of the suit that I had on, I don’t know, but inside my legs: heat rash,” Thomas, now 36, shares. “I’m itching, scratching. My mom asked me what’s going on. I end up showing her, and then she goes to the set medic, and they give her some lotion.”

“But the lotion had something that made it burn so bad,” he continues. “Somewhere on the internet is a photo of me just standing in my trailer, and my face is angry because I was on fire.”

When this happened, Thomas shares, it was the same day that his character had to jump on the back of ZigZag, played by Max Kasch. According to Thomas, Kasch was well over 6 feet tall, while he was less than 5 feet at the time.

“I do this big jump lying on the back of him, but I got to wrap my legs around them, and it is in pain the whole time,” he shares. “Max might have got really choked out.” 

Despite the heat rash and other challenges of being away from home for more than three months for the first time, Thomas says the film was a great experience and accomplishment to have so early in his career. 

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“Everything about it was such an eye-opening experience, and to make my dreams come true at that young age, to see myself on a film screen. It really means a lot when I look back on it. I got a chance to accomplish something very early. It has been a great journey ever since,” Thomas shares. 

Since Holes, Thomas has starred in various projects like Hurricane Season, Roll Bounce and If It Bleeds. 

Recently, he partnered with Froot Loops for “Follow Your Ears” campaign which celebrates the 1,000+ Hip-Hop shoutouts to the brand in songs. Fans could comment which songs featured the Froot Loops mention for a chance to win Kristopher Kites designed jewelery inspired by the brand. 

Holes is available to stream on Disney+.