The inclusion of the plotline about Michael Myers' early days at the mental asylum under the care of Sam Loomis is a nod to a plotline added in by John Carpenter for the television viewing of the original Halloween (1978). As told by Carpenter, when the original film was first sold to television, they demanded added scenes to replace the edited portions of the murder scenes. So Carpenter recalled Donald Pleasence, the original Sam Loomis to film scenes of him at the hospital taking care of Michael.
(at around 54 mins) 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 Kyes and P.J. Soles walk down in the original film when Michael Myers drives past them in the station wagon.
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's production was delayed due to the death of Moustapha Akkad, the producer of all eight previous movies. Akkad died of severe injuries as a result from the terrorist attacks at Jordan in 2005.
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.
The movie was not released in the United States 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.
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 (2009), another horror remake. Compton had also auditioned for that role but lost the role against Panabaker.
In an interview, Rob Zombie said he went into the meeting with the Weinsteins with two films in mind: one being strictly just Myers and his childhood, then the remake. Unfortunately, they shot the idea down. This is why in the remake that the first half of the film focuses on Myers's childhood.
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 (1978) was the only girl who was a teenager.
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.
In an early scene in the film, the movie White Zombie (1932) is playing on television. The band White Zombie, whose name comes from the film, is where director Rob Zombie first gained attention in the 1980s and 1990s.
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 Misfits' band mascot since the band's inception.
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.
Heather Bowen was a finalist for a walk-on role through a contest on the official "Halloween" Website. She won overall through a lottery-style drawing by Moustapha Akkad at the Haddonfield 25 Fan Convention.
Rob Zombie revealed making Halloween with the Weinstein's was "a miserable experience for me, and so I was very reticent to do the second one. I did do the second one, and I thought, 'Okay, well the first one was a miserable experience, but it did well, so maybe it'll be easier the second time?' It was worse. Oh my God. I felt like they weren't trusting me on the first one because they wanted to make sure it was a hit and now they weren't trusting me not to f*** up their hit." Detailing why the experience was not one the creator looks back on favorably, he said: "They would show me scenes from Halloween to try and make a point and I'd be like, 'Yeah, I know. I made that movie. Why do you show me that like I've never seen it before?'" "We made a behind the scenes documentary for the making of Halloween. That has somehow gotten lost in the vaults. That shows how messed up everything was and what was going on when we were making those movies."
(at around 48 mins) Big Joe Grizzly does an impression of Strother Martin from Cool Hand Luke (1967) 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.
This was Rob Zombie's first experience using the 2.39:1 scope aspect ratio. He was not comfortable using it for this film and returned to his preferred 1.85:1 aspect ratio for its sequel which was shot in the Super 16 format using 1.85:1, although he used the scope format for The Lords of Salem (2012) & 31 (2016).
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 asylum by killing two 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.
(at around 49 mins) When Michael Myers escapes from the sanitarium he finds his way to a truck stop. At the truck stop he follows a man (Ken Foree) into the men's stall. After killing the truck driver Michael, puts on the truckers jump suit. The very same jump suit actor Ken Foree wore in George A. Romero's Dawn of the Dead (1978).