Production began with two weeks of filming in 1991. The filmmakers and cast reunited 25 years later to complete the story.
Neither computer-generated effects nor lookalikes were used in the flashback sequences.
The "NASA stock footage" that opens the film was shot on a home-built animation stand built by visual effects supervisor Kurt Zendler in his living room.
The story concept of Russian involvement in the central mystery came entirely from actor Joe Santaniello. While preparing for his interview, Santaniello concluded that astronaut Bo Cunningham could only have effected his plan with significant help from Russian agents. After telling his theory to directors David Dodson and Mark Dodson, he and the filmmakers developed the idea as central to the story.
During production, in the interest of experiencing the hardships of his character, actor Jeff McVey spent each night in the desert, sleeping in a tent at the Red Rock Canyon State Park location, miles from the closest town.