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As filming commenced, Weller’s experiences grew increasingly taxing. The heat inside the suit cased him to lose around 1.5 kilograms per day, leading to frustrations that almost resulted in his dismissal from the project. Another actor, Lance Henriksen, was even interviewed as a potential replacement. To remedy Weller’s discomfort, a ventilation system was ingeniously installed in his armor.
Navigating the environment was another hurdle; the cumbersome nature of the RoboCop suit made entering a car practically impossible. Consequently, the film crew creatively filmed these scenes with just the upper half of Weller’s costume visible. Weller often wore less than ideal attire underneath, such as a type of underwear termed “samba canção.”