 The decision to cast Billy Campbell as Cliff Secord caused mixed emotions amongst Disney executives . Director Joe Johnston and creator Dave Stevens believed Campbell was perfect for the role , but Disney wanted an A @-@ list actor . Johnston eventually convinced Disney otherwise . Campbell was not familiar with the comic book when he got the part but quickly read it , in addition to books on aviation . He also prepared by listening to 1940s period music . The actor had a fear of flying but overcame it with the help of the film 's aerial coordinator , Craig Hosking . To ensure his safety , Campbell was doubled for almost all of the flying sequences in conventional aircraft . Ultimately , a scale model devised by ILM puppeteer Tom St. Amand was used for all the rocket pack scenes . 
