As part of his creative contributions to the series, Sorbo played an instrumental role in casting fellow actors to appear with him as regulars on the show. Sorbo notes that Cobb is the only actor he did not personally choose. "It was a choice by Tribune who had worked with him before. All they had to do was show me a photo of him and some of his work on guest spots he's done. Physically, of course, he's the guy! He was Tyr. Keith is very much a thinker. He keeps to himself quite a bit. I don't know where Keith comes from. He's got his own style of working. He gets into his character and plays with it off-camera a little bit while we're on the set. He's very focused on his character."

The characters of Beka Valentine and Andromeda were cast together, says Sorbo. "Lisa Ryder, who plays Beka, and Lexa Doig, who plays Andromeda - I met with them and five other actresses in Los Angeles. Beka was the hardest person to cast in the show. It's the one character that everyone had a different idea of what the character should look like or who she should be. There were a lot of fights in that one. She took forever to cast. At the screen-tests, where I do the scenes with the actresses to see if there's any chemistry and what our working relationships might be like, I felt she was number one. They still wanted to look for others, as they weren't convinced. I told Lisa, 'I've been there. They called me seven times for H:TLJ over a three month period!" Ultimately, Lisa Ryder captured the Valentine role, leaving the role of Andromeda to Lexa Doig. "We all liked Lexa a lot, but she wasn't right for Beka," Sorbo explains. "She wasn't physically or old enough for the part. They were looking at other people that none of us were really crazy about. After talking to the studio people I think Lexa began looking at the Andromeda character in a completely different way," chuckles Sorbo.

For the alien role of Rev Bem only one man had the part. "Brent Stait's reading was so far superior to everyone else!" says Sorbo. "It was like 'This guy's the guy!' He's such a good actor. When I see Brent in person, I keep forgetting that this is Rev Bem, the Magog!" As the ship's engineer, Seamus Harper, the blond-haired Gordon Michael Woolvett, fit the mold. "We had our eyes set on someone else, but we hadn't met Gordon Woolvett yet," says Sorbo. "We saw one Canadian guy about eight months ago, who was doing a show in Toronto. I actually called him and asked him, 'Do you want to do the series? It will give you a movie career.' He wasn't interested. Then they found Gordon. I saw his tape about two weeks before I moved up here. I said, 'This guy's a freaking phenomenon! He's great!' Gordon has a very strong personality, and he works hard. We had to believe that he was a genius, yet he was in a surfer dude's body! He was a Malibu California guy. [Harper] can turn a toaster into a Jaguar. He can make anything happen for you."

The final cast member of the series was for the mysterious role of Trance Gemini, a 'lavender skinned' young pixie of a girl with a pointed tail. Sorbo recalls that Laura Bertram was the first actress that he met upon arriving in Vancouver to begin the series. "By consensus, everyone loved her right off the bat when we looked at the [audition] tapes. She was great. She was just like how she is on the show. She came in and said, 'Oh, I'm so excited to work with you!' She's like a little kid on the set. She's only 22 years old. She's wonderful." (06.11.00 Cinescape)