Sam Elliott is the only principal actor in the film who wears a worn and faded uniform. When he was issued a brand new uniform for the film, he called costume expert Luster Bayless and asked for instructions to properly age his uniform. The actor carried out the process in his motel bathroom.
The film's U.S. television debut on TNT in June 1994 attracted the largest viewership ever for a movie broadcast on basic cable. More than 23 million people watched all or part of the two-night broadcast.
Sam Elliott has been trying to produce a movie based on the life of General Buford ever since this film's release.
During the Atlanta premiere, Martin Sheen was increasingly annoyed by an audience member seated behind him who offered a running commentary of the film's characters, and what was about to happen. When the lights came on for intermission, Sheen turned to confront the person and realized it was former President Jimmy Carter.
Three Chamberlain brothers were at Gettysburg, although only two are in the film. John Chamberlain was a doctor who had come down to visit his brothers, Joshua and Thomas. When Lee invaded Pennsylvania, John stayed with the 20th Maine to help. He treated the wounded of the 20th Maine on Little Round Top, and helped afterwards at various field hospitals. Joshua said "Split up, another close one like that and it could be a bad day for mother" to John and Tom after a shell exploded in the trees over their heads as they climbed up Little Round Top together.
Ken Burns: the soldier who tells General Hancock, "Please, sir, you must get down. We cannot spare you."
Ted Turner: Confederate States of America Colonel Waller T. Patton, the forbearer of two future U.S. Army Generals. During Major General Pickett's charge, some Confederate troops come to a fence that they have to climb over. Patton leads the charge, then gets shot down in front of the fence.
Olivia Maxwell: a young Marylander beside the road who says "I thought the war was in Virginia", as the Army of the Potomac marches towards Gettysburg. Pro-Confederate sentiment was strong in Maryland; the state remained in the Union only because Abraham Lincoln placed it under virtual military occupation and suspended habeas corpus. Had Maryland seceded, Washington, D.C. would have been completely surrounded by Confederate territory. In the Director's Cut, other females appear in another scene and one has two short lines.
Kelly Farrah: The Confederate officer Colonel Chamberlain guns down with his pistol during Little Round Top, right before he sends Tom to plug the hole in the line.
Emile O. Schmidt: General Gibbon, who speaks to General Buford outdoors at dusk following the first day of battle. Schmidt was a professor and head of the theatre department at nearby Gettysburg College.
Ron Maxwell: One of Hancock's aides on the third day, when Hancock is introduced to Colonel Chamberlain.