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- A full face mask resembling a wrinkled bulldog was originally constructed for the character of Barf, but Mel Brooks quipped that 'if they were going to hide John Candy behind a mask, he might as well hire someone else for half the price'. A nose and upper lip piece was tried next, which Candy approved but again Brooks did not. They finally settled on animatronic ears connected to a hairpiece, a small nose application and a patch over one eye just like the dog from the [Our Gang] shorts. The costume was operated by three people. John Candy operated Barf's tail using a hidden control in his paw, while two assistants each controlled an ear. Candy's costume was powered by a 30-pound battery that he wore on his back.
- Every time Dark Helmet has his face covered, his voice is lower and more basal, similar to James Earl Jones when he played Darth Vader. In the DVD commentary, Mel Brooks says that the idea of Dark Helmet's voice changing whenever his face was covered was actually Rick Moranis' idea.
- In the scene where Dark Helmet is dressed in safari clothes searching for Lonestar and the others with binoculars, he is on top of a floating vehicle. In reality, the vehicle isn't floating or suspended on wires of any kind, but on top of a platform that was surrounded by mirrors that reflected the sand around it to give it the appearance of floating.
- In the DVD commentary, Mel Brooks talks about how difficult it was playing the Yogurt character. The gold-colored makeup gave him a terrible rash on his face and neck, also his knees were hurting constantly since he had to walk around on his knees even though he was wearing kneepads. Brooks also goes on to say that in spite of the difficulties, he enjoyed playing as Yogurt tremendously and that it was all worth it.
- The scene in which Dark Helmet (Rick Moranis) is playing with his dolls was not in the script. Mel Brooks came up with the idea on the set one day, and told it to Moranis, who then improvised the entire scene, including the dialogue.
- Mel Brooks asked George Lucas's permission before spoofing Star Wars. George Lucas trusted Mel Brooks to make the film after reading the script, because he loved Blazing Saddles and Young Frankenstein. Lucas said that he could only make this film if no merchandise was manufactured which is why all the movie related products are shown in the movie. Said merchandising shown in the movie: - bed sheet - flame thrower - lunch box - cornflakes - towels - Yogurt figure - toilet paper - shaving cream - place mat - action figures.
- John Candy ad-libbed the line, "Oh, that's gonna leave a mark," after standing up without undoing his seat belt.
- The "chestburster" scene in the interstellar diner features John Hurt, whose character suffered the same fate in Alien. In an obscure joke, the creature emulates the singing frog in the classic Warner Brothers cartoon One Froggy Evening. One of the ships parked outside is the Millennium Falcon from Star Wars.
- When President Skroob meets the twins, he tells them to "chew [their] gum." This is a reference to "Doublemint" commercials featuring twins.
- When Dark Helmet asks for transformation into Mega Maid, Colonel Sandurz says "Prepare for Metamorphosis". Then Dark Helmet says "Ready Kafka?" [?] Franz Kafka wrote a novel called The Metamorphosis. Mel Brooks also makes an obscure reference to The Metamorphosis in The Producers.