Producers Andrew Form and Bradley Fuller decided not to make a sequel to the 2003 movie. But the fans kept coming to them, asking how the family got that way and wanting to know several unanswered questions in the 2003 version (some of them include how Monty lost both of his legs, to how Sheriff Hoyt lost his front teeth, and how Leatherface got his nickname). And after a meeting with Michael Bay, they let Sheldon Turner write the script for a prequel and they were prepared to make it.
Jordana Brewster initially got made fun of for the way she ran during filming scenes in which her character Chrissie had to run. Jordana said she's use to running on a treadmill in form, producer Andrew Form (and Jordana's future husband) told her that she looked like she was running in the 'Chariots of Fire', they told her to run messy with her arms in the air and not go in a straight line. Jordana said she ended up running faster then the camera operators could go and was like, 'Well, how's that?' with a laugh
When Eric gets his face wrapped in cellophane by Sheriff Hoyt that's actually real, Matt Bomer's head was actually being wrapped in Saran Wrap, R. Lee Ermey said he was very concerned for him. They left a small gap opening at the bottom of Matt's chin for him to breathe but that didn't help much, so when ever he was having trouble breathing he would indicate by knocking his knees together
Diora Baird who portrays Leatherface victim Bailey would later go on to star in the 2009 spoof Stan Helsing (2009) where her character among others must evade a collective of killers based off horror icons, one a blower wielding skin masked psychopath titled Pleatherface, a parody of Leatherface.
New Line had to pay $3 million more than it expected to in order to keep the series in the studio fold after Dimension Films made a pricey deal with original rights holders Tobe Hooper, Kim Henkel and Robert Kuhn.
Jordana Brewster said while filming with future husband Andrew Form 'Everyday Andrew wore these work boots to the set, and if I was lying down in the shot or there was equipment in the way, I'd look for his shoes. It was comfortable just to know he was nearby.' They married in 2007.