The hell beast that chases Cordy when she first arrives in pylea is the same kind of creature that Tucker uses to attack the prom in The Prom (1999).
The actor playing the Hell Beast (Lee Whittaker) had to endure 4 hours of costume and prosthetic fittings to transform his appearance. Once in costume, Whittaker was unable to go to the bathroom.
Despite fan speculation that the Pylea episodes were due to Julie Benz being unavailable for the conclusion of the Darla storyline, Tim Minear says the writers decided they were "weary of the Darla drama" and wanted the finale to be something "totally unexpected" instead. Julie Benz confirmed that she left because the writers had "played out the storyline as much as possible."
Production designer Stuart Blatt says the location department had found a movie ranch with a standing set for a "Tijuana town," which they dressed for the Boxer Rebellion scenes of Darla (2000) and used again for the village of Pylea. He says, "it just so happens that the Chinese province town which looked a lot like Mexico also happens to look a lot like England, or Pylea or any other medieval pseudo Euro-space, alternative dimension with two suns kind of world". The set designers added timbers to the existing clay buildings, put thatching on the roofs, and created stalls for merchants and vendors. Blatt says their animal wranglers brought in "medieval chickens and goats and pigs and yaks" and old chariots were reconstructed to create the vehicles.
The scene in which Angel opens the portal to Pylea was shot outside Paramount Pictures, where the series is filmed.