THey were toying with usign Soundwave but realized they'd rather do him right by giving him his needed screen time in the sequel.
Blackout's original CGI tests had Soundwave's head, but somewhere along the line they decided to make him Blackout instead.
There was an old design for Ratchet in red and white that was not used. Megatrons old head design was scrapped too. I remember seeing a very early concept art of Megatron with a arm cannon and blocky parts, although it doesn't really count as a scrapped design. If I could find the picture I would post it. All I can remember is that the site had a large quantity of the movie concept art.
Blackout was at various points throughout the production of the film known as the following characters: Grimlock Soundwave Vortex Incinerator Crazy eh?
Grimlock Arcee Soundwave Shockwave prowl Wheeljack Skywarp Thundercracker Mirage Um I can't think of any more but thats about it(POST 2,000!!!)
If they had made Grimlock a helicopter I would've jumped off a cliff in despair. Granted it would've been a very small cliff, maybe only a few feet high, but I still would've jumped I tell you!
Wheeljack and Prowl where apparently in the original line up of Autobots (back when they wanted 7 a side) before any real script had been written.
I'm pretty sure Scorponok was (when Blackout was going to be Soundwave) originally going to be Ravage, just can't remember exactly where I heard it.
According to a leaked script treatment a few monts ago, The Air Craft Carrier is suposed to be The reformated Decepticon ship, Nemesis. When Soundwave and his Decepticons arrive on earth, The Nemesis attacks a military Air Craft carrier sinking it. The Nemesis has the abillity to change it's apperance like the transformers in the next movie.
If we are just going on names I guess you could say Brawl as the subtitles called him Demolisher. Or maybe Demolisher as it was really Brawl on screen.
i remember there being on the dvd some where, pictures of this "air craft carrier" transformer, it probably got dropped, concidering how HUGE it would of had to be. not to mention, they'd never be able to make a big enough toy to of it to make every one happy. even if they made it ultimate, they'd still be unhappy people with it. maybe it will appear in the next movie? heck a battle on giant transforming air craft carrier with optimus prime and megatron fighting would be cool, but it would be too close to being the same battle they had on unicron in armada, which bags the question, why bother having it again? lol we've seen it! just not on the big screen. though i guess it would be cool, but big play sets aren't popular no more, which is why toys like fortmax aren't seen any more, well unless you go to the kitchen isle at tru lol then they got some pretty huge toys, so if they did make it, it would of probably of just been a leader class, IF that, heck maybe just a ultra class. or worse... *deluxe class*...