Author Existence Failure: Trinidad Silva, who played Raul, died in an auto accident before shooting all his scenes. The film is dedicated to him. The movie also had to abort his subplot, where the poodles got revenge.
Deleted Scene: Included, along with Al's reasoning on why they were deleted... "Because they suck!"
Several of the deleted scenes involved a subplot with Teri's (Victoria Jackson's) secretary, who was completely taken out of the movie. Unfortunately, the actress playing the secretary wasn't told this until she saw the premiere.
When R.J. discovers that his office has been wrecked and his Mooks disarmed, he screamed after that, but that portion was trimmed. Oddly enough, it ended up in the theatrical trailer as part of a montage of screams.
There was a whole subplot concerning the thugs. The Head Thug was deathly afraid of insects & other creepy crawlies. Later on, after Stanley's rescue, they attempt to steal the telethon money (stored in a suitcase). However, they accidentally grab a look-a-like suitcase that appears identical...containing Philo's bug collection. Back on the highway, Head Thug opens the case, full of massive & still very much alive roaches & beetles, and totally freaks out...causing the car to careen off a bridge and kill them all!
In a cut scene, when George & Bob first arrive, U-62 has a news anchor named Fred Parker who clearly has anger issues and has had it with his job. During his newscast, he reporting about the City Hall/budget cuts situation (later shown in the movie with Pamela & Noodles) when the camera guy, who's been noisily eating potato chips, let's out a huge belch. Cue nutty newsguy violently turning over his desk, "I HAVE HAD IT!!!". Pamela finally gets her much-wanted news position...which, of course, really is her forté.
"And there's this scene where... get this... I go to the BANK!"
Hey, It's That Guy!: The cast includes Michael Richards and Fran Drescher before either was well known, though, prior to this movie, Michael Richards was a cast member on the ABC sketch show Fridays, one of many sketch shows made as competition for NBC's Saturday Night Live (and, according to many fans and TV historians, the only one that would have been a perfect replacement for SNL had ABC not screwed with its timeslot and SNL not have recovered from having Jean Doumanian as a showrunner).
David Proval from The Sopranos is one of the kidnappers of Stanley.
Plus, Joe Early runs shop at the local high school but isn't all that emotional. (cue rim-shot)
Old Shame: Apparently, if you bring this film up to Michael Richards, he will not react well, though he did appear in the cast commentary.
Prop Recycling: The producers struck a deal with KOED (OETA/PBS in Tulsa) to build a news set in their studio. The Tulsa network used the set for their own broadcasts for a couple years afterward.
What Could Have Been: The role of Philo was originally written for Al's friend Joel Hodgson, but he was busy working on Mystery Science Theater 3000. Yankovic and Levey then offered the role to Crispin Glover. Glover, however, only wanted to play Crazy Ernie. Neither Yankovic nor Levey felt that Crazy Ernie was right for Glover, so they passed on him.
In addition, Christopher Lloyd was also considered to play Stanley if Michael Richards declined. Ironically, both Lloyd and Glover had previously co-starred together in Back to the Future.
Sylvester Stallone was going to cameo as the helicopter ride ticketer during the Rambo parody scene, but had to cancel due to schedule issues.
David Spade was one of the people who auditioned for the role of Bob.
If the movie hadn't been picked up, Yankovic would have toured Europe opening for Michael Jackson.