"From Another Planet With Love" was banned in the 1970s after a support group for atomic bomb survivors complained about comparisons between bomb victims and Spell Aliens.note That's literal, by the way - the episode was actually rerun several times without incident or comment, but a third party published a set of cards that happened to describe Alien Spell as "an A-Bomb Survivor" (which isn't inaccurate, but can really only invite bad-taste comparisons). Tsuburaya banned the episode outright as a result of the controversy, as well as all elements from it.
In 2011, "Super Weapon R-1" was banned in Japan after the Fukushima Daiichi disaster.
Fatal Method Acting: An aversion: From the Ultra Wiki: During filming of "The 300-Year Revenge", a giant prop of Ultraseven's hand malfunctioned and nearly killed Yuriko Hishimi when she was supposed to fall and land on it. She asked the producers not to air the episode and they complied. "Searching for Tomorrow", the replacement episode, has Seven catch and drop off the fortune teller with his hand, and that was accomplished with blue screen, as was Seven's hand in "The Courageous Battle".
Misblamed: During the Cinar Dub's run on TNT's Toons 'Till Noon block, it was commonly believed that Cinar was responsible for the significant cuts and edits to the series. In truth, these changes were made in 1994 by the TNT network to make some of the episodes suitable for pre-parental guidelines TV. This practice stopped once the parental guidelines were put into place, and Ultraseven was allowed to air unmolested.
Tsuburaya has a self-imposed ban on Episode 12.note The monsters in that episode were deemed to be a somewhat tasteless reference to the survivors of the Hiroshima and Nagasaki bombings Strangely enough, the banned Episode 12 was dubbed and broadcast in the Statesnote Alien Spell is made out to be a vampire of sorts, and can even be found online.
Out of the Hawaiian Dub, only episodes 21, 22, and 35 survived.
In the Cinar/Turner dub, all episodes were dubbed, but between 1985 and 1994, Turner's own video copies of episodes 5, 6, and 7 disappeared.
Nowadays, "Super Weapon R-1" is banned due to parallels to the Fukushima-Daiichi disaster, although it can still be found on DVD releases.
The Other Marty: Yoshiko Toyoura was cast as Anne. When Toyoura took a film offer instead, Yuriko Hishimi was cast. Hishimi ended up wearing a small male UG uniform, as Toyoura was much taller and her uniform didn't fit Hishimi.
Reality Subtext: Kohji Moritsugu, Dan's actor, said that filming days were very busy where typically he would wake up at 5 AM and only get home until about 11PM. Suddenly Dan suffering exhaustion and burn-out for the final two episodes feels more real.
Unfinished Episode: "The 300-Year Revenge". It was intended to be the twenty-third episode of the show and would have featured an alien called Alien Talk. It only became known in the 90s when a documentary on the production of Ultraseven discovered it.
Was originally supposed to be a more hard sci-fi show similar to Lost in Space called The Ultra Garrison, but someone urged a rewrite due to being too similar to rival show Captain Ultra, and the show was turned into Ultra Eye, where Dan was supposed to transform into Redman, who was also Ultraman Junior. The Capsule Monsters were supposed to be Peguila, Antlar, and Red King, but Tsuburaya wanted to do more with their budget, so the capsule monsters became new monsters. Ultra Eye was reworked into Ultra Seven and the rest is history.
When Turner Program Services was shown the finished dub, they found it to be subpar, and after failing to sell it to another network or syndication, the episodes were locked away until 1994- when they realized they never got run, they were given to TNT to run as part of their Toons Til Noon and MonsterVision blocks (for the former, the eps were edited to be suitable for kids and families; for the latter, the episodes ran uncut).
The Ultra Garrison proposal would have revolved around a team of astronauts and Robot Buddy "John", who lived in a space station called Mother and were Earth's first line of defense against alien invaders. The concept came off as too derisive, and the executives ordered Tsuburaya to rewrite it.
In addition to Ultraman Junior, there would be both good and bad monsters from Earth and space respectively, and the good Earth monsters would fight on humanity's side. Ultraman Gaia saw this idea come to fruition.
In one draft, Dan would have been half-R-alien (possessing ESP), half-human.
One of Seven's preliminary costume designs looked similar to Ultraman Mebius.
Most of those designs lacked an Eye Slugger, but did use elaborate headdresses and chestpieces.
Ultraseven was originally going to blue, but due to the blue-screen matte process, it was changed to red to prevent blend-in.
The series was originally intended to take place in its own continuity, where the events of Ultra Q and Ultraman never took place. Traces of this can be seen in the final product, as there is no mention whatsoever of Ultraman nor his adventures with the Science Patrol, Seven himself exhibits many differences when compared to other Ultras (though Ultraman Taro and Ultraman Zero, the latter being Seven's son, resemble him more closely.), and his superior looks exactly like him rather than Zoffy. The Heisei Ultraseven series and Ultraseven X ran with this idea.
Alien Guts was originally meant to have a bulbous exposed brain in order to emphasize his intelligence and potent mental powers, but Eiji Tsuburaya rejected it for being too grotesque.
The suckers on Guyros' tentacles were originally meant to be eyeballs.
"The Wandering Planet" was initially written as an episode of Ultraman, while Rigger's role was for Pagos. Agira was a last-minute addition, as the role was initially meant for Windam, but Executive Meddling demanded a new monster.
Miclas was originally meant to be killed in the Alien Guts two-parter rather than Windam.
A capsule monster based on Hachiko existed in early concepts.
Working Title: Ultra Eye and Ultraman Jr.were both considered for the show.
Writer Revolt: Akio Jissoji wanted to make an episode that didn't focus on monsters or weird-looking alien invaders, "The Nightmare of The Fourth Planet" however TBS (the produces behind the series) didn't want to greenlight it because it didn't have any monsters. So Akio Jissoji decided to write a script involving every monster from Ultraman and Ultraseven and refuse to write anything else until that script or the previous one were greenlighted. With the alternatives being letting Akio Jissoji go or producing the no doubt extremely expensive episode, TBS relented and allowed "The Nightmare of The Fourth Planet" to be made.
You Look Familiar: The Robot Chief was played by Dr. Niwanote Alien Prote's human disguise's actor. He'd later play Alien Nackle's human form (and voice him) in Return of Ultraman.
Ren Yamamoto, who played the human antagonist in Ultraman Episode 11 "The Ruffian From Outer Space", plays the human form of Alien Icarus in "The Strange Neighbor". He would turn up later in Episode 25 as a UG member and at least twice in Ultraman Taro as different characters.
The terrified salaryman from "The Green Terror" turns up as a local in Episode 41, reacting to events the same way.