Harrison Ford was offered the role of the older Indiana Jones, but he turned it down, since he thought television had nothing to offer his career. However, Ford appeared as a middle-aged Indy in season two, episode five, "Young Indiana Jones and the Mystery of the Blues", where he recalled one of his early adventures.
Filmed in twenty-three different countries, traveling over one hundred sixty-five thousand miles (aproximately six times around the world). Cast and crew shot for one hundred fifty-two weeks, making this the longest location shoot in history at that time. The series featured over fifteen hundred speaking parts, fifty thousand extras, for whom over one hundred twenty thousand meals were served. Enough 16-millimeter film was shot, to go from New York City to Phoenix.
George Lucas wrote an extensive timeline, detailing the life of Indiana Jones, assembling the elements for about seventy episodes of this show, starting in 1905, and leading all the way up to the feature films. Each outline, included the place, date, and the historical people Indy would meet in that episode, and would then be turned over to one the the series writers. When the series came to an end, twenty-eight of the seventy stories had been filmed.
Had the series been renewed for a third season, Young Indy would have been introduced to younger versions of characters from, or mentioned in, Raiders of the Lost Ark (1981): Abner Ravenwood ("Jerusalem, June 1909") and René Belloq ("Honduras, December 1920"). Other episodes would have filled in the blanks between existing ones ("Le Havre, June 1916", "Berlin, Late August, 1916"), and there would even have been some adventures starring a five-year-old Indy (Including "Princeton, May 1905").
For one of his brief appearances as the middle-aged Indiana Jones, Harrison Ford sports a beard. This is because he was filming The Fugitive (1993) at the time his scenes were shot, and he didn't have time to shave it off.
In close up shots of 9-year-old Henry Jr., you can clearly see that his actor, Corey Carrier, has deep brown eyes instead of Harrison Ford's trademark greenish-hazel eyes, or Sean Patrick Flannery's bright blue eyes.
A number of actors from the Indiana Jones film franchise have appeared in this series, though not all of them as their movie counterpart, as they would be too old for their character (except Harrison Ford, who played 50-year-old Indy in a flash-forward). Paul Freeman (Belloq), William Hootkins (Major Eaton), Terry Richards (the Hapless Swordsman in Cairo), Wolf Kahler (Dietrich), Vic Taliban (Barranca), Kevork Malikyan (Kasim), and of course Harrison Ford (Indiana Jones).
Sean Patrick Flannery's Indy hat isn't a true Herbert Johnson Poet. The crown is not as tall, and the band is too wide. You can see the genuine Poet hat in season two's "... the Mystery of the Blues" genuinely worn by the genuine Indiana Jones, Harrison Ford.
In the pilot episode, Miss Seymour says to Henry Jr. that the Sphinx was built "around 2500 B.C." truthfully, there's great dispute about this, and nobody really knows exactly when the Sphinx was built. However, I wouldn't consider this a continuity error, as it's in-keeping with the available knowledge of Egyptian history in 1908.