Sheri Moon Zombie's brother has a cameo as a police officer in the opening shootout scene. He was originally only on the set as a visitor, but director Rob Zombie put him in the scene because he knew how to handle firearms well.
Around one hundred digital effects shots appear in the film, mostly to create gore. The scenes involving objects coming into direct contact with skin (like throat slitting, people getting shot in the head or neck, or stabbings) were created digitally. The violence that didn't involve direct skin contact (like people getting shot in areas covered by clothing) were achieved practically. Rob Zombie originally intended to create all of the special effects using only techniques available in the 1970s, but time constraints prevented this.
The film originally had a subplot involving scenes with Dr. Satan. In an interview, Rob Zombie said that he cut these scenes because "seeing Dr. Satan in this film would be like seeing Chewbacca in Bonnie and Clyde (1967)". The scenes were eventually restored for the DVD.
The house used as the Firefly farm in this film was recreated on the Sable Ranch in Santa Clarita. Prior to filming, the house was located in the middle of the forest, and had been standing there for a long time. It was used in many films throughout the 1990s.
Rosario Dawson originally had a small part as a nurse in the film. Her character was cut out of the theatrical release for Rob Zombie's decision of not having any Dr. Satan in the film. Her character was killed off within forty seconds of her debut to the film.
The shoot out at the beginning of the film is very reminiscent of Australian bush-ranger Ned Kelly and his gang's last stand at Glenrowan. The armor, and the scene's presentation, are very similar to other film representations of Ned Kelly's tragic final defense.
The Family Media Guide claims the word "fuck" and its variations are used 224 times in this film, however other sources list the count at 560 which, until the release of Fuck (2005) was a record (the previous holder was Nil by Mouth (1997) which had a count of 470).
Matthew McGrory injured his ankle prior to shooting. The crew had to find a 7'4" stunt double to replace him during the scene near the beginning where Tiny is dragging a corpse through the woods. The double played Tiny up until he takes the burlap sack off his face, at which point he is played by McGrory.
The anchorman is named Derek Sanderson after the NHL player of the same name who played for the Boston Bruins during the '70s. Director Rob Zombie has mentioned during multiple interviews his affinity for the Bruins as a child growing up in Massachusetts.
The name Charlie Altamont was inspired by The Rolling Stones documentary Gimme Shelter (1970), in which a Hell's Angels member brutally stabbed a youth to death at Altamont Speedway in Northern California. In this film, Charlie "gives shelter" to the Firefly family.
This movie had to be cut seven times in order to receive an R rating from the MPAA. According to Rob Zombie, the censors had an issue with the film's overall tone, specifically the motel scene between Priscilla Barnes and Bill Moseley. This scene had to be cut by two minutes for the theatrical release; the cut footage was restored in the DVD version.
Sheri Moon Zombie was emotionally drained during the shooting of a scene with William Forsythe that required her to cry. She was so affected by the scene - which took two to three hours to film - that she did not come into work for two days afterward.