Larry DiTillio's script was originally deemed too expensive to produce, owing to several new models and a lot of light and shadow work. However, producer Hal Sutherland suggested that costs could be cut by making it a two-parter. This meant DiTillio had to write a prequel story (which became part 1) primarily using stock footage from earlier episodes. As such, Part 1 was written months after Part 2 and Ditillio still thinks the first part is one of his worst efforts and the second part one of his best.
Storyboard artist Don Manuel designed the new characters Lord Masque, Melaktha (described as a Georg Stanford Brown type) and Stanlan (described as young Luke Skywalker type). Masque was eventually released as an action figure by Mattycollector in 2016.
The heroic characters are twice seen sleeping in a tent. Orko is floating in his sleep, covered by a blanked, with his hat on a floating hat stand. When he wakes, he is briefly seen without his hat, but covers most of his head with his pillow. In the original storyboards, Ram Man's feet were supposed to be pumping in and out in time to his heavy snoring, but this joke was omitted from the final scene.
In the original script, the disguised version of Masque is referred to as 'Racca' and the commander in the Fortress in the Sands who brings He-Man the control box is called 'Sylus'.