The film was re-edited from the pilot episode of the TV series "The Man from U.N.C.L.E.". For the TV version, broadcast as "The Vulcan Affair", all of Will Kuluva's scenes as Mr. Allison were cut and reshot when it was decided to replace him with Leo G. Carroll as Mr. Waverly. But his scenes were left intact in To Trap a Spy. As this film version of the TV pilot was being prepared, there was legal wrangling over the use of the name THRUSH for the enemy organization. As a result, the word WASP is overdubbed in the theatrical version whenever THRUSH is mentioned.
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