Darren Criss got the part of Blaine after a nationwide open audition, in which anyone could upload a video onto Glee's Myspace page singing one of two songs they allowed. He originally auditioned for the role of Finn.
On the day of her audition, Lea Michele was involved in a car accident right outside of the studio. She came into the audition pulling shards of glass from her hair.
Cory Monteith didn't sing in his first audition video. He instead produced a beat using makeshift drums. The producers liked his personality and originality so much they called his agent and requested he fly to Los Angeles for a live audition.
While filming scenes, Kevin McHale (Artie) had a habit of tapping his feet to the beat of the music. On several occasions, scenes had to be reshot because the tapping was audible.
The role of Quinn Fabray was not cast until the night before filming began.