To make himself look like an average out of shape middle aged man Tom Hanks didn't exercise and allowed himself to grow pudgy. Production was then halted for a year so he could lose fifty pounds and grow out his hair for his time spent on the deserted island. During this hiatus, Robert Zemeckis used the same crew to film What Lies Beneath (2000).
To see the island that Cast Away was filmed on, put -17.609277,177.0397 into Google Maps and zoom in all the way on satellite mode. The beach that Tom Hanks writes HELP on and sees from the peak is the eastern most part of Monuriki, Fiji.
Some crew members were left on the island for a few days to survive and learn some skills. They used some of their survival techniques in the movie for the character of Chuck. They were: having trouble lighting a fire, opening a coconut, talking to a volleyball, collecting packages washed up on the beach, and catching fish.
Contrary to popular belief, FedEx did not pay the filmmakers anything for their presence in the movie. The director has made this clear in a number of interviews. While FedEx was very concerned when they heard about the project, they had no objections to the finished script and offered support during filming, with the company later stating that the movie was very good for FedEx business in general and in overseas markets in particular.
Virtually all the sound, including dialog, in the scenes on the island - about an hour and a half of screen time - had to be replaced in post-production. Sound man William B. Kaplan made a valiant attempt at getting usable sound on the island, but the nearby surf made it impossible, given that many of the scenes needed to be very quiet.
In the film, Chuck draws a picture of Kelly (Helen Hunt) on the wall of the cave. In the movie As Good as It Gets (1997), Simon Bishop tells Carol Connelly (also played by Hunt) 'you're the reason cavemen chiseled on walls'.
The production employed several local Fiji islanders in the surrounding archipelago, including the neighboring Mana Island about a mile away. The locals were allowed to keep some of the supplies and tools as tokens of their help.
Tom Hanks said that the hardest part of losing so much weight was not eating any French fries for a long time, and the thing that helped him the most in this process was drinking a great deal of coffee every morning.
Early in the movie Kelly gives Chuck a pocket watch for Christmas. She explains her grandfather used the watch on the Southern Pacific (Railroad). This is a foreshadow to Chuck's later dilemma where he is stranded in the South Pacific.
When Chuck Noland realizes a Russian FedEx van is stuck after being fitted with a parking boot, he immediately wrangles a crew of employees for a makeshift "sort" in the middle of Red Square. A Fed Ex sort is designed to separate packages into zones/trucks based on which part of the country they'll be routed to once they reach the airport. The process is so ingrained in Noland's psyche that even when marooned on the island, he gathers several Fed Ex packages from the ocean that have floated ashore, checks their routing destinations and performs a "sort" right on the beach.
As Chuck attempts to paddle off the island the first time he is wearing his underwear on his head you can clearly see he is wearing "Calvin Klein" underwear. Robert Zemeckis also directed Back to the Future (1985) where Marty McFly's "Calvins" were a running gag.
"Wilson" is the manufacturer of the ball used in the movie. But other Wilsons have played an important role in Tom Hanks life and career. Hanks' wife is actress Rita Wilson. And Hanks' first TV role was "Kip Wilson" in Bosom Buddies (1980).
The trivia items below may give away important plot points.
A FedEx commercial during the 2003 Super Bowl telecast featured the final scene of the film where Chuck returns the package to its sender. In this version the woman answers the door; when Chuck asks what was in the box, the woman replies, "Just a satellite phone, GPS locator, fishing rod, water purifier, and some seeds. Just silly stuff."
During a Q&A session at USC, Robert Zemeckis was asked what was in the unopened package. He replied that it was a waterproof, solar-powered satellite phone. To hear him say it for yourself on the DVD, do this: Start at the Special Features Main Menu and enter the Video & Stills Galleries. When you see "Raft Escape" press left on your remote to highlight the "World Of Time" logo. "World On Time" is the slogan that was on the FedEx box Chuck delivered to the house at the end of the movie.
Alan Silvestri wrote 24 minutes of score (including over seven minutes for the final credits) for a 143-minute film. Aside from the Russian chorus and the Elvis Presley song from the beginning, there is not one single note of written musical score in the film until Noland leaves the island (1 hour and 43 minutes into the movie). Only then does the musical score come in: an oboe, piano and strings are all that Silvestri uses. Every musical cue is a variation on the same melody, which is heard in full at the end.
In the beginning of the film a FedEx truck delivering a package to the ranch house drives under a gateway arch that has the names "Dick" on the left and "Bettina" on the right incorporated into the arch. At the end of the film when Chuck goes out to return the package to the occupant of the ranch house, the portion of the arch containing the name "Dick" has been ripped out, presumably due to the divorce action being initiated during the beginning of the film.
When Chuck and Kelly are curled up on the couch just before Christmas, the camera pans down the fireplace mantle, and you briefly see a basic sailing certification diploma that Chuck had earned. This explains why Chuck knows how and when to use his raft and sail at the right time through the surf.
The film's theatrical trailer controversially revealed Chuck's escape from the island and his reunion with Kelly. Robert Zemeckis's previous film What Lies Beneath (2000) was similarly criticized for revealing plot twists in the trailer. Zemeckis responded by saying "We know from studying the marketing of movies, people really want to know exactly every thing that they are going to see before they go see the movie. It's just one of those things. To me, being a movie lover and film student and a film scholar and a director, I don't. What I relate it to is McDonald's. The reason McDonald's is a tremendous success is that you don't have any surprises. You know exactly what it is going to taste like. Everybody knows the menu."
The moment before Chuck removes his tooth in the cave, he tells Wilson his dentist in Memphis is called "Dr. James Spalding". In the German dub, the name is changed to "Dr. James Volley" because few Germans are familiar with the American label "Spalding". In the Hungarian version the dentist is called "Dr. James Speedo".
When Bettina explains where each road leads at the intersection, she points toward the direction of her ranch and says "you'll find a whole lot of nothing all the way to Canada". Arlington Ranch, where they filmed the ranch scenes, is located in Canadian, Texas.
When Chuck is aboard the doomed Fed-Ex flight, he has his shoes off and loses them in the crash. Much later in the movie when Chuck is on a plane returning to his homeland he is shown wearing shoes, one of the first signs of his lifestyle transformation.
As Chuck's "welcome home party" is ending a coworker states that he has to "brief Chuck about his upcoming meetings". The actor that plays this coworker is Geoffrey Blake, the same actor that plays Jenny's boyfriend at the "Black Panther party" in Robert Zemeckis and Tom Hanks' Forrest Gump (1994).
Near the end of the movie, Kelly explains to Chuck that during his absence, the NFL team Houston Oilers became the Tennessee Titans and narrowly lost the Superbowl by 1 yard. This is in reference to Super Bowl XXXIV (2000) (played on January 30, 2000 in Atlanta) where the Titans played the St. Louis Rams and lost 23-16. The final play of the game involved Titans wide receiver Kevin Dyson receiving a pass from Titans quarterback Steve McNair but then being tackled 1 yard short of the end-zone by Rams linebacker Mike Jones. Tennessee could have potentially tied the game (with an extra point) or won it (on a 2-point conversion). This play has now been widely known as "The Tackle" and remains both the closest regulation end to a Super Bowl and (as of 2012) the last time the Tennessee Titans played in one.