Development House on Haunted Hill was the first film produced by American production company
Dark Castle Entertainment.
Joel Silver and
Robert Zemeckis had discussed remaking
William Castle's
1959 film as early as 1997. Malone stated that Rush was committed to the material and took the role seriously.
Elizabeth Hurley was initially considered for the role of Evelyn Price, but by February 1999, Famke Janssen was ultimately cast in the part. Taye Diggs was subsequently cast as Eddie, the ex-professional baseball player attending the party, and agreed to appear in the film after Rush signed onto the project. Ali Larter, who had previously completed
Varsity Blues (1999), was cast as Sara Wolfe, a woman who poses as her ex-boss, film executive Jennifer Jensen; the film marked Larter's third screen appearance.
Saturday Night Live star Chris Kattan was cast as Watson Pritchett, the caretaker of the building. Terry Castle stated that Kattan was cast in the part for the sake of
comic relief, and that the filmmakers allowed Kattan to "just [be] who he is." For the role of Dr. Vannacutt, the deranged head doctor of the hospital, singer
Marilyn Manson was at one point considered, with exteriors of the house's driveway being shot in
Griffith Park near the
Griffith Park Observatory. Adler commented on the unorthodox nature of the house: "Instead of being a typical sort of haunted house, this [one] is much more modern, with a touch of
Deco. It's not what you'd expect to see." Larter stated in an on-set interview: "The set is dark and dirty, and everyone's been sick, and [Taye Diggs] and Chris [Kattan] keep me laughing. We really have had a good time." The "Terror Incognita" roller coaster at Price's amusement park featured in the beginning of the film is actually
The Incredible Hulk Coaster at
Universal Islands of Adventure theme park at
Universal Orlando Resort in Florida. The film was shot on
35 mm film stock, the
negatives of which director Malone
flashed in order to reduce the contrast of the picture, giving it a visual appearance similar to the film stock used in the early 20th century. with additional makeup design by
Dick Smith in his last film credit. One of the monster figures featured in the film during Price's underwater hallucination sequence was a creation of Smith's that was intended to be used in
Ghost Story (1981) but was ultimately not featured. Malone, struck by the appearance of the figure—which consisted of an eyeless, noseless human head with an enlarged mouth—was granted permission from Smith to use it in the film. The tentacular morphing mass of ghosts featured at the film's climax was designed by KNB Effects, and was inspired by the visuals of
H.P. Lovecraft's novels, as well as resembling the
Rorschach inkblots used in psychiatry. According to Malone, much of the visual elements were actually not
computer-generated, and were actually made up of footage shot by the production crew, which was grafted together to form the mass. This included an exposition scene showing how Sara came to receive an invitation to the party: While working as a production assistant on a film set, Sara is fired by her boss, Jennifer Jenzen (played by
Debi Mazar), the feisty vice president of a motion picture company. Two versions of the scene were shot, during which Sara hands Jennifer a bag delivered for her; inside is a music box with a
jack-in-a-box-trigger which cuts the handler's finger. Jennifer throws the box in the garbage, and Sara discovers the invitation to Price's party inside of it. Another scene removed from the film last-minute, according to director Malone, was a scene in which Sara falls through a collapsing floor when she and Baker are being chased by The Darkness. After falling two stories below, Wolfe awakens in a subterranean
crematorium filled with the ashes and corpses of the hospital's dead patients. There, she is attacked by reanimated corpses who rise out of the ashes, terrorizing her and tearing off her overcoat. As a result of the scene's removal, there remains a
continuity error in the final cut of the film, in which Wolfe's overcoat disappears from her body in-between scenes. A final epilogue scene completing the Jennifer Jenzen story arc was also filmed, featuring Jennifer arriving at the house with a realtor, which she is to inherit. As she enters the front door, a bloodcurdling scream is heard, and the realtor is revealed to be Dr. Vannacutt. Director Malone said the scene ultimately was removed after the cutting of Jenzen's exposition scene, as well as for having a comical tone that did not fit with the rest of the film. All three deleted scenes from the film were included on the 2000 Warner Bros. Home Video release of the film on DVD in the bonus features section. == Music ==