One day on set, the winds were very high and blew a piece of lighting equipment onto a ferris wheel full of extras, injuring several of them. Miley Cyrus had just finished shooting a scene next to the ferris wheel when the accident occurred.
Miley cyrus and Billy Ray expected the film to be released theatrically in theaters instead the film being released on Disney Channel as a Disney Channel Original Movie, they did not want the film to be like an extra longer regular episode of the TV series.
The water was 55 degrees in Rutledge Falls, Tennessee for the Travis and Miley Swim Scene. Lucas Till and Miley Cyrus suffered through 2 takes. During the 2nd take Lucas had to spend about 90 seconds in the water being filmed beckoning to Miley who was having REAL second thoughts about the 2nd take. It took 45 minutes for them to warm up.
For the purpose of this movie, the band Rascal Flatts rewrote the lyrics of their song "Backwards" to fit the younger audience. The verse "You get your mind back, your nerves back, your first heart attack back" was changed to "You get your mind back, your nerves back, your achy breaky heart back" as a reference to the 90's hit "Achy Breaky Heart", sung by Billy Ray Cyrus who - in this movie - plays Hannah Montana's father Robby.
In the scene of Lily's birthday party, the band that is playing as Hannah's backup band is the real life band Days Difference. However, only three of the band members are in it: Jeremy (keys) and Jonathan Smith (drums) and Micah Ricks (bass). Micah's brother, Jeremiah, was sporting facial hair at the time of filming and Disney did not like that but he was on set with the rest of his band.
The smoke that can be seen coming from the tail pipe of the Blue F150 just before the scene where Miley gets out of the truck to meet Blue Jeans is actually steam from a fog machine that is being operated by a mechanism attached to the throttle. Disney wanted to keep the movie green, even going so far as using disposable cutlery made from compressed corn starch in catering.
In the original script actress Dolly Parton (Miley Cyrus' s God mother) who played a recurring role as main character Miley Stewart's Godmother Aunt Dolly in the TV series had a part in the movie but was latter dropped after the script was fully finished and her character did not fit in the script or film.
Stars Melora Hardin, whose other movie 17 Again (2009) opened a week earlier in U.S. theaters. Both movies were top-billed by Disney Channel stars, Zac Efron for the latter, Miley Cyrus for this movie. They both appeared in High School Musical 2 (2007) where Efron was the lead and Cyrus had a five-second cameo.
The trivia item below may give away important plot points.
The final dinner/banquet scene where Hannah is invited to dine with the mayor was filmed in the historic Maury County courthouse in downtown Columbia, Tennessee which was built in 1904. The crew actually removed the original doors to that entrance to the courthouse to install the custom made revolving door unit which was necessary to film the pivotal scenes that show Miley transforming back and forth from Hannah to Miley and vice versa. Once filming wrapped, the original doors and entrance were restored.