Dawson Casting: Richard Falomir, who plays Ricky Fitness, is in his early 30s while Ricky himself is 14. Or 19. It's not consistent.
Deleted Scene: According to this article, there was supposed to be a "Garage Door Escape" commercial done by Mega64, but it was pulled by the network before it could air, due to the implications of survival in the commercial.
Real-Life Relative: Christian Jacobs's son, Oskar, guests stars in "Summer Camp!" as Chauncey, the Aquacadet who models himself after MC Bat Commander.
Squick: Averted in the making-of Slushi commercial (from the "Uberchaun!" episode), according to the Mega64 podcast: the actual slushie used had candy in it to recreate the colors of sushi (watermelon for wasabi, black licorice for seaweed, etc.) with sherberet and ice cream to hold the candy in place. They expected the kids to take a sip, figuring the concoction would be gross, but the kids thought it tasted good, and proceeded to chug it, even after the director yelled "Cut!" The guys said they felt guilty having to pry away the cups because they really didn't want to make more.
Throw It In!: In "Cobra Man!" there's a moment where the Aquabats are ripping off their groundskeeper uniforms and the chinstrap on Crash's hat gets caught on his nose. According to the 'bats' commentary it was an accident but it fit the show's humor so well the crew didn't do another take.
The pilot episode, Tortilla Trouble, shows a few stark differences.
A completely different theme song.
The show followed a 2 shorts format, with the Aquabats playing a concert as a wrap-around, but with the Gloopy commercials. They also had an awards ceremony where a member of the band would get an award for a thing they did in the live-action segment. The award in the pilot is the "Dude-Man Award", which went to the Aquabat with the most 'dude' in the episode. Crash won the award for taking a boulder to the head. The episode then ended with a performance of "Awesome Forces!" a song on their 2005 album "Charge!!"
Ricky had a catchphrase, “Don’t look at me!”, which did pass onto the series proper, but not as intentionally cheesy.
The Dude is visible by a white outline, and Eaglebones doesn't have the falcon glove that summons her; nor does he summon her by shouting "I summon The Dude!"
Similarly to the animated segments, the whole show was narrated. The animated segment also happened after the live-action segment, unlike the series proper where they segue into it with one of the Aquabats saying "...It's a CARTOON!".
Jimmy used a jetpack that was not seen anywhere else in the actual show.
The Parody Commercial is tied right into equipment the Aquabats use in the show, rather than a generally goofy product from Gloopy. There were two commercials; the aforementioned one that had the hovercraft that's seen at the start of the Tortilla Trouble segment, and a commercial for a product called 'Insta-Bro!': A cool older brother in a box that you can bring to parties.
, there was supposed to be a "Garage Door Escape" commercial done by Mega64, but it was pulled by the network before it could air