 Evangeline Lilly was one of the last actors to be found for the  show, but since she is Canadian, the producers werent sure if she  would be able to play the part. They pushed back all of Kates  scenes when they where shooting the pilot, just to be sure that they  could get a green card for Lilly. It wasnt until they had shot  almost every scene without the Kate character that Evangeline Lilly  was finally granted a green card and signed on. The same day Lilly  was put on a plane in Canada and went directly in to shooting.