The audience members in the talk show scene were hired for $50 each, and they were told they would be the first audience members of a new talk show. This was filmed at a suburb of Dallas, Texas.
According to Sacha Baron Cohen, Harrison Ford is in the only scene that was scripted, and was the only actor that was in on the joke.
After filming the scene with presidential candidate Ron Paul, Sacha Baron Cohen and his camera crew were driven out of the state by a cop they hired. The reason for this being the threats to Sacha about the Secret Service coming after him. This was confirmed on the Blu-Ray commentary track.
Ayman Abu Aita filed a lawsuit against Sacha Baron Cohen for falsely depicting him as a terrorist and lying about the interview. Aita previously served in Al-Aqsa Martyrs' Brigade, a Palestinian terrorist group, and spent two years in an Israeli prison for shooting Israeli soldiers. At the time of filming, Aita was a representative of Fatah, which is not considered a terrorist group. David Letterman and Larry Charles are also named as defendants in the suit. Allegedly, Sacha Baron Cohen had claimed that he had received death threats from the Al-Aqsa Martyrs' Brigade.
The velcro suit scene was done in two different places. Before Sacha Baron Cohen could get on stage, he was thrown out and banned from other events. He mentioned in a commentary track that he and his crew had to sneak into another fashion show and do makeup while inside. His crew was then attacked by guards on the way out, but Sacha made it on stage with the camera rolling before he was arrested and interrogated.
James McCartney: Uncredited, as himself. In the first fashion show sequence, as the camera pans the audience, he appears briefly with his father, Sir Paul McCartney.