Michael Angelis, the narrator for the United Kingdom version of Thomas and Friends was originally cast as the voices of James and Percy. After the American test audiences heard his recording, his part was deleted as it made the characters sound too old. The roles went to Susan Roman and Linda Ballantyne respectively.
Isle of Mann taxi drive/firefighter John Bellis was originally cast as the voice of Thomas. After his recording was heard by American test audiences, they disliked his Liverpudlian tone as it made Thomas sound too old. The role went to 'Eddie Glenn'.
Despite the removal of PT Boomer (played by Doug Lennox), his character does appear during the film. Originally taking part in the final chase sequence, extensive editing had to be done to trim down the shots where he rides on the back of Diesel 10.
People that worked on the original series also worked on this movie, namely, David Mitton (as model unit creative consultant), David Eves (as model SFX supervisor), Steve Asquith (as model supervisor), and Terence Permane (as director of photography for the models section).