In a 2019 retrospective on the film for The Hollywood Reporter, Herek talked about some of those casting travails, revealing that the role of Rufus — which it’s difficult to imagine anyone other than George Carlin playing — was particularly tough to cast. Even as shooting began and jumped between Arizona (standing in for California) and Italy, the role had still not been filled. “We reached out to all sorts of people, Eddie Van Halen included, but we were a movie that was not on anybody’s radar,” Herek said. “We wanted Eddie to be involved in some way, because we’re constantly talking about Van Halen in the movie, and then we say, ‘Well, why not Rufus?'”
When that failed to pan out, the production looked at other rockers with some acting experience, like Beatles drummer Ringo Starr and the Who’s lead singer, Roger Daltrey. Eventually, it was determined that the part should probably be played by someone who was, you know, funny — and as luck would have it, two of Bill & Ted‘s producers were acquainted with Carlin, who agreed to take the part at basically the last minute, a development which thrilled both of the stars. “I went to the library as a kid to listen to George Carlin comedy albums, and seeing his work on television, I was a fan of his from my teens, so to meet him was extraordinary,” Reeves remembered. Winter called the legendary late funnyman “a cool glass of water,” remembering him as “reserved, just a very gentle guy, very respectful, not the public persona at all.”