Kelsey Grammer's Sideshow Bob and a family therapist voiced by Minnie Driver were originally going to be in the film, but for some reason their scenes were cut.
Isla Fisher, and Erin Brockovich-Ellis also recorded lines for the film, but their scenes were cut.
Kevin Bacon had a small cameo with his sons, Exon and Kris P. as an alternative Flanders family living outside of the dome. The scene was eventually cut.
Demand Overload: The Simpsonize Me website that was launched concurrently with the movie saw so much traffic during its early life on the internet that it frequently saw downtime. The fact that the site also utilized high-quality animated graphics didn't help either.
Enforced Method Acting: In order to make her sound properly emotionally drained, David Silverman had Julie Kavner record Marge's goodbye monologue to Homer close to one hundred times.
First Appearance: Of Homer's license plate number "1PHL07", which is a reference to The Bible. Previously, whenever it was shown in the series, it was always a different number. Starting with the episode "Homer the Father", however, it is consistently "1PHL07".
Maile Flanagan was the original voice actress for Colin, but she was let go at some point in production and Tress MacNeille re-recorded the character's dialogue.
Edward Norton originally recorded the part of the man who gets crushed by the dome using a Woody Allen impression, but the crew felt the voice was too distracting, so Dan Castellaneta re-recorded the dialogue with a different voice.
Throw It In: Hans Zimmer produced a choral version of Spider-Pig for the soundtrack just for shits and giggles, but the music worked so well with the epiphany scene that the producers placed it there. Turns out to be an overblown gag that snowballed out of control, as FOX also had to secure the rights to the song, and Zimmer had to redub it into different languages! It even became a hit single in several countries, making it, at a scant 61 seconds, the shortest recording ever to chart.
A Simpsons movie has been planned since the 1990s, but the writers couldn't figure out how to stretch the plot to feature-film length. Episodes that were considered for a feature-length movie are "Kamp Krusty" (which became the first episode of season four) and "Bonfire of the Manatees" (the first episode of season 17). Before his death, Phil Hartman had expressed interest in doing a live-action Troy McClure film.
Though the producers claim the film changed so often that at least another film's worth of material made it to storyboard and/or animatic, only a few minutes of deleted scenes appear on the DVD.
Hank Scorpio from "You Only Move Twice" was going to be the villain instead of Russ Cargill. Hell, they not only share the same voice actor, but the same voice. They decided against it because Scorpio was found to be too likeable to turn into an all-out villain.
Speaking of Cargill, he was supposed to have a completely different design from the one seen in the movie.
The film was going to have more PG-13 language than just Marge's one "Goddamn."
In the original storyboard, the silo containing the pig's poop had "pig shit" written on it.
Apparently, it was originally supposed to be President Schwarzenegger who managed to KO Cargill (with a tree branch!), instead of Maggie dropping a boulder on him.
Instead of going to Seattle, Marge and the kids were going to go on The View where Russ Cargill shows up, gets in a shotgun duel with Joy Behar, and has the Simpsons arrested.
Originally, Marge, not Grandpa, was supposed to be the one to have the prophecy at church, but the writers admitted they were a little disturbed by the fact the entire family would just ignore when someone like Marge would completely wig out, so they changed to the character that everyone ignored anyway.
A lesser example: Marge's line about what Homer was doing with the pig's "leavings" began as what Matt Groening described as "the world's longest shit joke," with Marge giving a Long List of different euphemisms for poop, none of which would register to Homer.