Props, costumes, special effects shots, and sets from Battlestar Galactica (1978) were used in this series.
Erin Gray was asked to dye her hair blonde for the role of Wilma Deering. However, as the first season progresses, her blonde hair begins to fade to her natural brunette coloring. In the second season, she was allowed to have completely brunette hair.
Gil Gerard's waistline flexed weekly, and even daily. Gerard was warned by producer Bruce Lansbury about feasting on the company's "open all day" craft service buffet. Buck's white skintight jumpsuit plagued Al Lehman (costumer) when Lansbury asked if wardrobe could make Gerard "slimmer". Lehman gave Gerard the nickname "the white polish sausage".
The series used footage of the British and French pavilions at Expo '67 in Canada to represent the futuristic buildings such as Dr. Elias Huer's office tower and Buck Rogers' apartment building.
United States broadcast of the second season was delayed until midway through the 1980-81 television season because of an actor's strike. During the strike, the series was retooled to make this more like Star Trek (1966) and Larson's own Battlestar Galactica (1978). The first season was based on Earth and the second was based aboard a deep space exploration vessel. The primary villains in the first season, the Draconians, are never seen in the second season and neither is Buck's friend and mentor Dr. Elias Huer, and Hawk (a "Mr. Spock" type character) is added as Buck's sidekick.