The star pushed his body to the limit to shoot director Darren Aronofsky's 2008 action drama, in which he portrays an ageing professional grappler attempting to make a comeback.
But Rourke admits the strenuous shoot took its toll on his ageing muscles and he was left so crippled with pain, he and his house help Javier broke down in tears at the thought that he was dying.
He says, "He (Aronofsky) gets the most out of you... I never did a backflip in my life, and you know, I'm no spring chicken - my legs are gone, my back is gone...
"So the night of the wrap party, I lived in a three-storey walk up (and) I had my trainer - literally I had to hold on to him. My knees were shaking, my legs were shaking. I got to the couch and started crying, started breathing real funny (sic). I couldn't speak. I had this really great gay houseboy, named Javier.
"I didn't know if I was dying - I called my priest, my doctor... So he explained to me what was going on, I was just exhausted. So I'm crying, Javier's crying, and Javier's crying more than I am so I'm thinking I must be in bad shape 'cause Javier's sobbing, screaming. He's going, 'Oh papi!' He's hugging me, we're crying together. I thought no more physical movies, that's it. I'm never gonna do a backflip, never gonna do a push up..."
But Rourke, 59, broke his own vow when he signed up to star in the mythological Greek epic Immortals, one of two action films he's got lined up.
He adds, "And (then) I got this movie (Immortals). It's not that physical, but I got another movie coming up and I do it all again."
The unnamed man was performing a six-storey jump last week (beg15Aug11) when a back-up safety mechanism failed to halt his plunge properly and he plummeted to the ground.
According to TMZ.com, the man was taken to hospital where it was discovered he had broken both his ankles.
The show's producers tell the website, "Safety is our first priority, and because of that we test these stunts repeatedly with trained stuntmen to ensure our contestants' well-being."
It's the second accident to plague the show this month - a contestant suffered minor injuries after the truck she was standing on collided with a stunt car.
The Apprentice star owns Trump Tower, a lavish 58-storey building situated in the heart of the Big Apple on Fifth Avenue.
It has attracted a host of superstar residents over the years, including Steven Spielberg, Sophia Loren, Michael Jackson and Johnny Carson, and now Trump has commissioned writers to come up with a drama based upon the building's rich residents, according to the New York Post.
Trump's representative Michael Cohen says, "Several major network and cable channel executives have already called, and a battle has begun to see where it will air."
The Hollywood hunk was recruited to replace Charlie Sheen after he was fired from the hugely popular sitcom earlier this year (11) due to his bizarre public behaviour.
However, TMZ.com reports that Kutcher has already prompted frustration among staff, who feel the two-storey customised mobile home is "over the top" and makes Kutcher look like a "diva".
The Get Him to the Greek star sparked speculation his relationship with Perry was in jeopardy when they placed their Hollywood Hills home up for sale earlier this year (11).
Brand fuelled reports of a rift when he was photographed holding hands with an unnamed woman on the set of his new film last week (end26Jun11).
But it appears the pair's union is as strong as ever as it emerges they have splashed out on a luxury new home in California.
Brand and Perry have bought a $6.5 million (£4.6 million), three-storey property, which was used in the first series of U.S. show The Bachelor.
The mansion reportedly boasts seven bedrooms, a pool, a guest house, nine bathrooms, a film screening room and even a bar.
Hong Kong tycoon and billionaire philanthropist Yu Panglin, who currently owns Lee's former two-storey home in the Kowloon area, had decided to donate the building to the city to pay tribute to Lee.
His plans to turn the house into a tourist attraction were given the green light in 2009 after locals and government officials approved the venture, in order to preserve Lee's memory.
However negotiations between Panglin and the Hong Kong government have now broken down, halting the project indefinitely, according to the Associated Press.
The Hong Kong government released a statement which reads, "Despite our efforts, we are unable to reach a consensus with the property owner over the scope of the restoration."
Enter the Dragon star Lee died in 1973, aged 32.
The Cast Away star and his wife Rita Wilson hired contractors at Storey Construction to build their Sun Valley villa in 2000, but took legal action against the firm after discovering faults in their work, including a leaky roof which nearly collapsed following the home's completion in 2002.
The two parties have been going back and forth through arbitration and tribunal hearings, and Hanks and Wilson took their case for $3 million (£1.88 million) in damages to officials at the Blaine County District Court in Idaho.
But members of the American Arbitration Association rejected their bid for compensation on Saturday (21May11).
The movie star couple was dealt a further blow after its was ordered to pay all legal costs for Storey Construction.
The Hollywood star is currently shooting the sci-fi blockbuster in Manhattan, but he hit headlines last week (ends13May11) after residents in the Soho district complained about the sizeable eyesore parked outside their homes.
The two-storey trailer, which features a cinema, a lounge bar and offices, as well as a full-sized kitchen, large bedroom and bathroom, had to be moved after Mayor Michael Bloomberg waded into the debate and demanded Smith relocate to a private car park, half a mile (0.8 kilometres) away from the movie set.
But Smith can't get his head around the scandal - because the public has never taken issue with it before.
In an interview with his former manager, Russell Simmons, on GlobalGrind.com, Smith says, "I don't really understand the controversy. Men in Black 1 and 2 and Hitch used the same trailer, in the same place. In fact, we use it every time."
And rap mogul Simmons has publicly shown his support for Smith - he's titled the blog post, 'If I Was Will Smith, I Wouldn't Move My Trailer One Inch'.
"I have good genes, but I'm a health nut. My favourite food (is) hot dogs with french fries. And I get a lot of exercise. I have a two-storey house with a very bad memory." Actress Betty White, 89, jokes about how she maintains good health.
The dedicated Terminator: Salvation actor insists he was ready to do anything his stunt double did in the movie - but he was always told that taking on falls and tumbles was too risky.
And he was upset when he was told to step back after one tense scene - so a stuntman could dive through a window.
He explains, "I just got up there and I went, 'I'm jumping'... I've jumped from three-storey buildings in my own life after bad parties and stuff.
"The insurance came around... and they were just begging me not to (do it)."