Development Fred Olen Ray wrote the film's story under the working title
Thunderblast, and was originally going to direct as part of two-picture deal with CineTel, following
Cyclone. The bullet-riddled hero was lifted by Ray and frequent collaborator T.L. Lankford from one of their earlier scripts, which eventually found its own way to the screen as
Deep Space. According to Ray's biography, the character moment where Busey pulls a bullet from his shoulder was expanded with material excised from the equivalent scene in
Deep Space, which was abridged at the request of producer
Moshe Diamant due to his distaste for graphic gunshot wounds.
Bulletproof was intended as a step up in class for the fledgling CineTel, and the casting director told them that Ray—who had a reputation for campy films—lacked the pedigree needed to attract the reputable star they were looking for to headline. In response, president Paul Hertzberg removed Ray from the project and assigned directorial duties to
Steve Carver, who boasted more mainstream credentials. This paved the way for
Gary Busey's signing, while Ray moved on to the lower-budget
Commando Squad for
Trans World Entertainment. Although he received financial compensation for his dismissal, his relationship with Hertzberg remained strained for several years. Photography was originally slated for July 1986, Busey mentioned wrapping up filming on the eve of an interview to
The Daily Oklahoman, which was published on March 6. While Gary Busey had vowed to clean up his act following his personal issues, Actor
René Enriquez was given the green light to participate by the producers of his regular show
Hill Street Blues, and was scheduled to start filming his part on
Bulletproof on January 6, 1987. However, he was unexpectedly called back to
Hill Street Blues on January 5. The actor remained committed to the feature, and the showrunners worked out their schedule to accommodate him. Far more serious were the film's financial problems. The preliminary budget was pegged at $1.75 million. However production butted heads with the unions and ran out of money as costs skyrocketed past the $5 million mark, which resulted in several shutdowns and confrontations over unpaid wages. ==Release==