As I understand it, the US networks weren't going to carry on purchasing Danger Man. Without a US sale the budget would have to be slashed and the quality would suffer. McGoohan had The Prisoner which he wanted to make instead and Lew Grade agreed to this.
Danger Man producer Sydney Cole (an ITC regular) was left without a series and without a leading man. Cole then produced Man in a Suitcase. It's not clear to me whether MIAS existed at all as a concept prior to Danger Man being cancelled or whether it was created specifically as a new series for Cole.
There are obvious similarities between the series in that they concern a single character who was/had been a spy and it was fairly straightforward to rewrite some unmade Danger Man scripts as Man in a Suitcase episodes, but MIAS wasn't a straight sequel to Danger Man.
I've never heard any suggestion that McGoohan might ever have played McGill and it seems unlikely that, even if The Prisoner hadn't been shooting at the same time, the US networks would want a series starring McGoohan which would then have seemed too superficially similar to the one they had just declined to buy.
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