A then-unknown John Larroquette provided the narration in the original Massacre à la tronçonneuse (1974). Despite becoming a distinguished actor in the years since, he happily agreed to reprise his role for the remake.
Erica Leerhsen screamed so loudly during her screen test that people in other parts of the building called the police to report that a woman was being attacked.
After learning about the remake, Andrew Bryniarski (Leatherface) went up to producer Michael Bay at a Christmas party and personally asked him for the role.
During the scene in the van with R. Lee Ermey (The Sheriff) and Jonathan Tucker (Morgan), Tucker forced the gun down his throat in order to make himself vomit every take. If you watch carefully you can see him spit the vomit out of his mouth in the scene.
On his final day of shooting, Eric Balfour stripped down, threw his wardrobe back to the crew, and walked off the set only wearing a baseball cap. Footage of his departure is shown in the making of documentary on the special edition DVD/Blu-ray.