For seven seasons, the crew of the Enterprise-D traveled across the galaxy, confronted terrifying enemies and wrestled with questions about humanity’s future. Yet some of the strangest stories from Star Trek: The Next Generation unfolded much closer to home—inside dressing rooms, beneath uncomfortable costumes and behind the cameras.
Premiering in 1987, the series initially faced enormous skepticism. Could another crew replace Captain Kirk, Spock and the beloved characters from the original Star Trek?
Even Patrick Stewart wasn’t convinced.
The distinguished Shakespearean actor reportedly believed the series would fail so quickly that he left his suitcases unpacked during his first six weeks in Los Angeles. Instead, The Next Generation produced 178 episodes, ran until 1994 and attracted more than 30 million viewers for its celebrated finale.
But Stewart almost never became Captain Jean-Luc Picard.
Gene Roddenberry reportedly imagined a younger captain with hair and initially resisted casting Stewart. Producer Robert Justman, however, recognized something commanding in the British actor and continued advocating for him.
Studio executives were reportedly so concerned about Stewart’s baldness that he attended an early meeting wearing a hairpiece. Ironically, the executives approved his casting but demanded that he remove what they considered a ridiculous toupee.
When the media introduced Stewart as an “unknown British Shakespearean actor,” Brent Spiner—who played Data—placed a sign on his dressing-room door warning everyone to beware of exactly that.
The joking reflected a genuine closeness that developed among the cast.
Stewart and Jonathan Frakes became lifelong friends, while Spiner served as best man at LeVar Burton’s 1992 wedding. Stewart, Frakes and Michael Dorn were ushers. Marina Sirtis and Dorn also formed a remarkably close friendship, although Sirtis has admitted that they could barely tolerate each other during the first season.
Their later chemistry became so convincing that fans speculated they were secretly a couple. Both actors denied that their relationship was ever romantic.
Their costumes created another kind of tension.
The original Starfleet uniforms looked futuristic but were painfully restrictive. The one-piece spandex suits reportedly pulled down on the actors’ shoulders and placed pressure on their backs. Stewart’s agent allegedly threatened legal action if the uniform caused lasting muscle or joint damage.
By Season 3, the production introduced more comfortable two-piece uniforms. The change was subtle on television but enormously important to the actors wearing them for long filming days.
Michael Dorn faced an even more demanding transformation. Becoming Worf required approximately two hours in the makeup chair. Then, during the second season, the production’s original Klingon forehead prosthetic was reportedly stolen.
The crew had to create a replacement, resulting in a slightly different forehead that attentive viewers can spot.
LeVar Burton suffered for his character’s appearance as well.
Geordi La Forge’s iconic VISOR was originally assembled using ordinary materials, including what has been described as a car air-filter component and a hair band. The finished prop became one of the franchise’s most recognizable designs—but Burton said it caused daily headaches.
The VISOR reportedly pressed into the sides of his head and limited his ability to see. During long stretches on the bridge when Geordi had few lines, it also gave Burton an unexpected advantage: he could occasionally close his eyes or fall asleep without anyone immediately noticing.
Producers considered restoring Geordi’s natural eyesight after the second season and eliminating the VISOR. They abandoned that plan after recognizing the character’s importance as a positive representation of disability.
The women of the Enterprise had their own carefully concealed costume secrets.
Marina Sirtis wore hairpieces for much of the series to create Counselor Troi’s flowing hairstyle. Gates McFadden’s fine red hair created continuity problems under powerful studio lights, so the production eventually supplied her with expensive real-hair wigs.
Sirtis later joked that she was jealous because her earlier hairpiece was made from cheaper synthetic material. By Season 4, she finally received a real-hair upgrade.
Even the famous Riker beard began almost by accident.
Jonathan Frakes returned for second-season rehearsals with facial hair grown during the 1988 writers’ strike. He expected to shave, but producers liked the more mature appearance. Roddenberry reportedly thought the beard gave Riker a suitably “nautical” quality.
It stayed—and became so closely associated with the character that “growing the beard” eventually became a pop-culture expression for a television series dramatically improving.
Some legendary performers nearly joined the adventure.
Whoopi Goldberg personally sought a role because of her admiration for the original series. Producers initially did not believe her request was serious, but she eventually became the mysterious and beloved Guinan.
Robin Williams was also interested in appearing. A role in the fifth-season episode “A Matter of Time” was reportedly intended for him, but scheduling conflicts with Hook prevented it. Matt Frewer ultimately played the part.
Wil Wheaton experienced a different kind of behind-the-scenes frustration. When the cast pursued higher salaries, producers reportedly offered to promote Wesley Crusher to lieutenant instead of increasing Wheaton’s pay.
His response captured the absurdity perfectly: What was he supposed to tell his landlord—that he could not pay the rent but had just made lieutenant?
What began as a risky revival ultimately became a television powerhouse. By the early 1990s, episodes reportedly cost close to $2 million to produce, while advertising generated tens of millions annually.
Yet the show’s real legacy was never just financial. Its uncomfortable uniforms, stolen prosthetics, improvised props and unexpected friendships helped create a future that millions of viewers wanted to believe was possible.
The Enterprise looked flawless on screen. Behind the scenes, however, it was held together by determination, friendship—and occasionally a car part and a hair band.
