The balloon in the balloon sequence was shipped from Goodyear in Akron, Ohio. It was handled by Navy balloonist J.J. Leonard, and was equipped with an automatic camera to avoid the weight of a cameraman.
Many actors who were in Pearl White's movies had roles in this film: Paul Panzer played the villain in the original serial, The Perils of Pauline (1914); Creighton Hale was the hero in White's serial The Exploits of Elaine (1914); William Farnum came out of retirement to play himself, appearing in the same costume he wore in Riders of the Purple Sage (1918). In addition, Louis J. Gasnier, who directed the original film (The Perils of Pauline (1914)), was a technical advisor on this film.
When the movie was screened to test audiences, there was one scene that had Pauline being attacked by a gorilla played by Charles Gemora. This was paying homage to the silent film where Pauline gets attacked by a gorilla. However, that scene scared women who left the theater holding on to their throats due to how horrific it was. As a result, the sequence was deleted. All that remains of this scene is a photograph.
According to an article in the 12 May 1946 edition of the New York Times, Betty Hutton did all her own stunts in this film.
There never was any scene with the heroine tied to railroad tracks in the original The Perils of Pauline (1914). The scene like that in this film is a recreation of a scene in a Keystone comedy called Teddy at the Throttle (1917). A similar scene also occurred in an earlier Keystone comedy called Barney Oldfield's Race for a Life (1913).