Director Rob Zombie revealed in an interview that his original script featured a much larger role for Captain Spaulding, played by actor Sid Haig. However, upon receiving word that Haig was in the hospital recovering from surgery, Zombie visited him at the rehabilitation facility and was alarmed by the drastic changes in his physique, most notably that he had lost a significant amount of weight. Zombie realized that Haig's health was in serious question, and he was forced to reconsider Captain Spaulding's prominence in the story while keeping Haig in the film since Lionsgate was going to shut down the film without Haig in it. After numerous rewrites, Zombie introduced the character Foxy Coltrane, played by frequent collaborator Richard Brake, as a way of filling in for the 3rd Firefly Family member without necessarily replacing Captain Spaulding altogether. Ironically, Zombie did not speak to Haig after he shot his role until his death.

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