Mel was in Brendan McCarthy's (co-writer) storyboards for the film for years from 1997. Mel was excited about it and said to Miller they needed to get it made before he turned 50.
Miller has never said Gibson was difficult to work with on the films (unlike Hardy), and in 1985 said that if he'd refused to do Thunderdome they'd have gone back to just doing the initial idea of it been another hero who stumbled across the tribe of children because he would never re-cast Max.
So it was all set. Then because of weather conditions they couldn't film where George Miller usually did in Australia so that delayed, and Mel decided to do his Passion project, and you know the rest after that film's release.
Was age an issue? Maybe a bit, he was late 50's by the time they started filming but it's not as if Tom Hardy was doing most of his own stunts or putting himself in danger. It was either a double or wire work, even when he's running in the citadel to escape the war boys the film's speeded up, and Harrison Ford was still doing Indy at 80 and a lot of the physical stuff, and Max is a less physical role than Indy.
So ultimately, I think Gibson didn't do it simply because his reputation was in tatters post-mid 2000's.
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