The film was mostly shot in South Pasadena, California, the same area where John Carpenter's original film was filmed. When Laurie notices Michael watching her and the girls at the library, Michael is actually standing in front of Laurie's house from the original film. Also, Laurie's house is located on the same street that Jamie Lee Curtis, Nancy Loomis and P.J. Soles walk down in the original film when Michael Myers drives past them in the station wagon.
Before deciding to go with Rob Zombie's version, the studio was about to green light "Halloween: The Missing Years", which would have been a prequel, set within Michael Myers' early days at the Asylum.
Of all the female leads (all the girls are supposed to be in high school including Judith Myers), only the actress playing Laurie, Scout Taylor-Compton was actually a teenager at the time of filming, much like how Jamie Lee Curtis who played Laurie in the original Halloween was the only girl who was a teenager.
The inclusion of the plot line about Michael Meyers' early days at the mental institution under the care of Sam Loomis is a nod to a plot line added in by John Carpenter for the TV viewing of the original Halloween (1978). As told by Carpenter, when the original film was first sold to TV, they demanded added scenes to replace the edited portions of the murder scenes. So Carpenter recalled 'Donald Pleasance', the original Sam Loomis to film scenes of him at the hospital taking care of Michael.
William Forsythe actually injured his leg prior to shooting, which is why his leg is in a cast in the film. In the script the character only had an arm brace, but Forsythe's leg injury was also worked into the film.
The movie was not released in the U.S. on Halloween weekend, as was the original, for fear of going head to head with Saw IV (2007). It was instead released two months earlier on the last weekend in August 2007.
At one point Dimension Studios considered making a crossover film featuring Pinhead from the Hellraiser (1987) series, following in the footsteps of Newline Cinema's horror crossover Freddy vs. Jason (2003). A poll was held on the official site, but response from fans was negative and the studio dropped the concept.
26 minutes were trimmed from the film for its theatrical release in Brazil, so it could get a broader rating, which translates to more screening times. In the end it received a rating of 14 years (kids over 14 can watch it without parental supervision), which is not the most restrictive available, yet meant that the film could only be shown after 9pm.
In an early scene in the film, the movie White Zombie (1932) is playing on the TV. The band 'White Zombie', whose name comes from the film, is where Director Rob Zombie first gained attention in the 1980s and 1990s.
In the opening scene of the movie, the song "God of Thunder" by 'KISS' is played and young Michael Myers is seen wearing a KISS t-shirt. KISS is a major influence on Rob Zombie's music career and the inspiration for the make-up and costuming for his band White Zombie.
'The Misfits were one of Rob Zombie's influences during his musical career, and the band's track 'Halloween II' is playing on the stereo during the kill scene while the couple are having sex in Michael's childhood home. Also, Tommy's costume is that of the Crimson Ghost character 'The Fiend'. This character has been used as The Misfit's band mascot since the band's inception.
One of the most complex scenes in the film was shot on Monday, February 26 2007, on the campus of Los Angeles City College. The day's shooting facilitated the use of 160 extras and about 100 crew people.
Heather Bowen was a finalist for a walk-on role through a contest on the official "Halloween" Web site. She won overall through a lottery-style drawing by Moustapha Akkad at the Haddonfield 25 Fan Convention.
When talking about Michael, Ronnie says "He's probably gonna end up cutting his dick and balls off and changing his name to Michel." Daeg Faerch would later play a character named "Michel" in Hancock (2008).
Danielle Panabaker auditioned for the role of Laurie Strode. Scout Taylor Compton was cast instead. Two years later Panabaker was cast as the female lead in Friday the 13th another horror remake. Compton had also auditioned for that role but lost it against Panabaker.
Big Joe Grizzley does and impression of Strothers Martin from Cool Hand Luke by saying "What we got here is ... failure to communicate" in a voice imitating him. The line in the movie is correct--BUT the subtitles adds the word "a" before "failure"--more grammatically correct--but not accurate.
Danny Trejo's death scene was cut from the work print after studio heads complained about it. Zombie lobbied to them, stating it was important to show how brutal and uncompassionate the character truly is. In the final cut, Zombie won and was allowed to put the scene in.
In the work print and director's cut of the film, an alternate escape scene was used. In it Michael begins his escape from the institution by killing 2 young & educated Harvard graduates orderlies while they are molesting a catatonic female patient in his room.
The couple having sex in Michael Myers' childhood home are killed in the exact fashion they were in John Carpenter's 1978 original. The teenage boy is pinned to a wall with a kitchen knife and the teenage girl is strangled to death whilst nude. Myers also wears a sheet over his body and the boy's glasses before he kills the girl, just as he did in the original.