Actor Allusion: When Zoey goes crazy in "Eat, Puke, and Be Wary", her archery skills resemble Katniss Everdeen's. Interestingly, in the Quebec dubbing of the show, Zoey and Katniss were voiced by the same woman.
Christian Potenza originally auditioned to voice Ezekiel, but was persuaded by Tom McGills to voice Chris..
The Island episode "Haute Camp-ture" was supposed to feature a Fashion Show-esque challenge, but the idea was dropped at the last minute. The episode's title was changed to "After the Dock of Shame" in some TV guides.
World Tour was originally to be called Total Drama, the Musical, feature only 15 contestants, and including visits to locations such as Italy, Hershey, Scotland, and Toronto, none of which made it in the final product note Though most were still featured in some way, such as being used in the Aftermaths.
Revenge of the Island has a few:
Cameo appearances by Leshawna, Harold, and Tyler were planned but scrapped the last minute. All three still made brief cameos along with the rest of the original characters in the first episode.
According to this article from 2008, Revenge of the Island was also originally called Total Drama Comedy in it's very early planning stages.
According to◊ Word of God, the original All-Stars line-up included Owen, Cody and Brick, but last minute decisions had them replaced with Gwen and Sam, and the cast cut down to 14. However Owen still managed to get a cameo in the finale, and Cody got frequently mentioned by Sierra and had his face appear in hallucinations. The same line-up also revealed plots that didn't make it into the season such as Courtney getting revenge on Heather note Possibly rejected once Gwen was added to the cast, Duncan getting revenge on Courtney, the continuation of Zoey's commando persona, and Scott once again having evil intentions by creating a new and improved strategy after analyzing past Total Drama episodes.
Cody was dropped because they thought his relationship with Sierra had been fully played out in World Tour.
Brick was replaced by Sam because he was 'easier to write'.
Anne Maria was also a part of the original cast before being replaced by an Island competitor.
And then there's a recently discovered trailer from late 2011 (two months before Revenge of the Island aired and almost two years before All-Stars actually aired).
According to his character bio, Max from Pahkitew Island was said to have psychic powers that allowed him to see only 3 seconds into the future. No traits of his psychic powers were shown in the actual season and was simply the Big Bad Wannabe.