The famous Girl scout scene, The Story Begins, was actually real. Actor Tim Joyce requested that the girls actually hit him and bring him to the ground to make the scene look real. Joyce reports that his kidneys were sore for a week afterwards! Talk about Method Acting.
Colonel Savage is played physically by Anthony A Vitello, but his voice is played by Tom McCray - AKA Tom Donahue, who can be heard every weekday morning on WECK 102.9 FM or AM 1230 in Buffalo.
One rule that the actors were given was that if a continuity error happened during a take, and they noticed it, they were suppose to call it out, or draw attention to it in their performance, so it seemed as if it really was meant to be there. And they called us amateurs.
The gloves worn by Tim Joyce and Dan Danforth in the show were made out of PVC rubber, and when the actors would sweat, a terrible odor would emit from them. So bad in fact that they had to bleach them out four times during the course of the shooting. At the wrap of the shoot, hey had a ceremonial disposal ceremony.
In the original script to the show, Sarah Palin was written in to be the villain. Her name in the script was ITEM 2012 and she was suppose to cause massive destruction. She was also a robot. Upon looking for an actress to portray Sarah Palin, they decided to try something else since they didn't want to get to political.