In his "E! True Hollywood Story" bio, Lee Majors says he started his show business career by hanging out with stuntmen, and occasionally working as one. Majors made sure that real stuntmen got plenty of work on the show.
Colt's truck was an early 1980s GMC 4x4 pickup, with a 6-inch lift and 35-inch Dick Cepek off-road tires mounted on a 16-inch chrome wagon-style wheel. It also had a custom-made chrome roll bar mounted with 4 off-road lights, and a custom chrome grille guard mounted with 2 off-road lights and a Warn winch. One unusual characteristic was a secret compartment in the truck's bed, used to stash away villains or hide weapons.
According to the E! True Hollywood Story (1996) biography of Lee Majors, Farrah Fawcett made a cameo appearance in the pilot, against the advice of her friends and manager. Lee and Farrah had just completed a messy tabloid-ridden divorce; she appeared on the show to show the public that they were separating on good terms.
Stunts took their toll on the GMC trucks, so several different trucks were used during the show's initial run, causing some inconsistencies in episodes. For instance, the 1980 model truck in the pilot had two square headlights and a light tan interior. For the rest of the series, it almost always had the quad headlight configuration of 1981 and newer models, with a dark brown interior. The truck always appeared to be a long bed model, but a short bed model was used in a few episodes. After huge jumps destroyed several trucks, a jump truck was custom-built, with a mid-mounted engine and a reinforced frame and axles.
Initially, TV execs were wary of doing a show about a stuntman who moonlights as a private investigator. They changed their minds when they heard a demo tape of Lee Majors singing "The Unknown Stuntman."
The theme song, "The Unknown Stuntman", became a minor hit in the early 1980s. It was credited to Lee Majors in the pilot, but was credited to Majors' character Colt Seavers in subsequent episodes. The lyrics include the line, "I've been seen with Farrah," a reference to Majors' ex-wife, Farrah Fawcett.