Casting the lead role of Cliff Secord was a struggle for the filmmakers. Disney executive Jeffrey Katzenberg even had one of the studio's then-staff writers, Karey Kirkpatrick, audition for the part. Kevin Costner and Matthew Modine were the first actors considered for the role. When they both proved to be unavailable, Dennis Quaid, Kurt Russell, Bill Paxton and Emilio Estevez auditioned for the part. Johnny Depp was Disney's favorite choice, while Paxton commented he came "really close" to getting the lead. Vincent D'Onofrio turned down the role and the filmmakers were forced to continue their search.