The final reel of the film to be completed was done so only five days before the world premiere in Wellington, New Zealand. The premiere was the first time that Peter Jackson had seen the completed film.
When Gandalf rides out, using the light of his staff to ward off the fell beasts so Faramir's team can get back to Minas Tirith, you see that Pippin is on the horse with him, even though there would have been no reason to bring him along. The reason is that this scene was originally filmed to coincide with Gandalf and Pippin's arrival at Minas Tirith, but was pushed further back as the story evolved.
The first shot of Sam's arm coming into frame holding Sting towards Shelob is actually Peter Jackson's arm
Lawrence Makoare, when wearing the Gothmog makeup, was called "Pimplehead" by extras who didn't know his name.
EASTER EGGS: One the Extended Edition DVD, Disc 1, as per the first two movies, go to the scene selection menu, to the last page. Press down until a ring icon appears next to the "new scene" phrase; Up comes a satellite "interview" of Elijah Wood, given by Dominic Monaghan using a German accent. Do the same thing on disc 2 to uncover an MTV skit featuring Ben Stiller and Vince Vaughn pitching LOTR sequels to Peter Jackson.
In every installment of the trilogy, one character says the subtitle of the film. In Fellowship during the council scene Elrond refers to the nine as the "Fellowship of the Ring"; in the Two Towers it's Saruman who says "The Two Towers" during a voiceover; and finally in this film, Gandalf tells the steward of Gondor and he can't refuse the Return of the King.
Scenes were re-shot with the Witch King because his helmet was too similar to Sauron's in The Lord of the Rings: The Fellowship of the Ring (2001) and Peter Jackson was concerned that audiences would confuse the two.
The first film in the trilogy had 560 computer-generated effects. "The Two Towers" had 800 and "Return of the King" has 1500.
Peter Jackson's children appear twice in the film: in Gondor, when the horsemen leave the city, and in Sam's wedding.
Director Cameo: [Peter Jackson] One of the mercenaries on the boats headed for Minas Tirtith.
Cameo: [Christian Rivers] Art Director and Storyboard Artist, appears as one of the Gondorian soldiers watching the beacon in Minas Tirith.
Cameo: [Rick Porras] The other soldier watching the beacon at Minas Tirith is the co-producer.
Additional scenes were filmed in New Zealand in 2003, in much the same way as new sequences were shot for The Lord of the Rings: The Two Towers (2002) prior to that film's release.
Sean Astin's daughter, Alexandra Astin, plays Sam Gamgee's daughter, Elanor. Sarah McLeod's daughter, Maisie McLeod-Riera, plays Sam and Rosie's son Frodo.
While filming the trilogy, Viggo Mortensen got so into character that during a conversation, Peter Jackson referred to him as "Aragorn" for over half an hour without Mortensen's realizing it.
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