This was the first Gerry Anderson TV series to make use of an early version of his Supermarionation marionette animation process, although the term was not coined until his next series, Supercar (1961).
The idea for Four Feather Falls came from music composer Barry Gray, who also wrote the first episode. Gerry Anderson later admitted that he didn't credit Gray as the series creator for no other reason other than he did not know such a title existed. "It's difficult to imagine," said Anderson some years later, "but we were desperately naive in those days."
The original working titles were "Two Gun Tex Tucker" and "Two Gun Tex of Texas" with the original setting was in the fictional wild-west town of Spelltown, Kansas.
Originally Tex Tucker was to have been aided by his obese assistant Buster and the pilot story included two other characters called Slim Jim and Jake Jollymop. Jake was replaced by Timothy Twinkle known as Ole Twink, the town's oldest resident, who in the final version was named Grandpa Ebenezer Twink and the name Jake was given to his grandson. Also, Martha Lollipop (later Martha Jones) was the storekeeper and she was assisted by Red Feather of the Kiowa tribe. The town's doctor was Angus McDougall, known to residents as Jock the Doc, and he was also the storyteller for each episode (which was later changed to Grandpa Twink as the storyteller). Other characters that didn't make it into the final version were Merry Myrtle, Mary Lou, Big Chief Four Feather and Saucy Sal.
Actress Denise Bryer had worked with Gerry Anderson on The Adventures of Twizzle (1957), and he wanted her to play some of the voices in Four Feather Falls. Anderson visited Bryer at her home with some scripts and asked her then husband, Nicholas Parsons, to help by reading some of the other parts, including the sheriff Tex Tucker. Anderson liked Parsons' interpretation and offered him the job of providing Tex's speaking voice.