There are lots of secrets of Star Tours
production as well as hidden in the ride itself, here are a few of them...
The work crews shown in the docking bays and control rooms of the film are actually members of the ILM model shop staff.
The sequence in the film where your ship enters a giant ice crystal was changed from the original story board. The original idea was that as the ship reached the end of the ice tunnel, it would be blocked by a smooth ice wall in which the audience could see the reflection of the StarSpeeder as it got closer. The sequence was shot, but when the rough cut was viewed, it was decided that things happened too fast to understand what was going on. The tunnel was then simply made to end with no reflection of the StarSpeeder.
The fuel tanker that your ship almost runs into at the end has on its side a hazardous materials sign and registration number. The registration number is Lucasfilm's phone number. The tanker also has the initials of the model maker who made the model.
The G2 maintenance droids in the second queue area are actually reworked geese from the old "America Sings" attraction from one of Tomorrowland's previous incarnations.
If you look at the right hand side of the view screen just before flying out of the StarSpeeder port, you can see the "Mighty Microscope" that used to be the entrance to "Adventures Thru Inner Space", the ride that Star Tours replaced.
The RX droid that pilots your StarSpeeder, Rex, is voiced by Paul "Pee-Wee Herman" Ruebens.
There's a long red tag hanging off of Rex's base that says "Warning! Remove before Flight!"
The numbers and letters on the baskets that revolve around the ceiling in the second queue area are actually the initials and birth dates of the imagineers that worked on the ride.
The mockup of the StarSpeeder 3000 that is being serviced in the first queue area is actually made out of wood.
The pipes in both queue areas are decorated with the designing imagineers initials and phone extensions.
C-3PO and R2-D2 in the first queue area
are the actual items that were used in the making of the original three
Star Wars films. Additionally C-3PO is actually gold plated with
an estimated $16,000 in gold foil.