Though already a martial artist and owner of a dojo, Nicholas Hill hadn't been active in competition prior to his role in the movie. As a promotional gimmick, Hill gained entry to the second World Vale Tudo Championships, where he faced Pedro Rizzo in a no-holds-bared match. Whereas the promoters expected this to be a one-time event, Hill was eager to compete and thus initiated a six-year career as a professional cage fighter.
Donald Gibb, who plays Ray 'Tiny' Jackson, is the only returning cast member from the original O Grande Dragão Branco (1988).
Veteran Asian star Philip Tan, who plays John, also served as the film's martial arts action choreographer.
Ron Hall had to audition for his role twice, the second time following a script rewrite that reduced his character's prominence.