Gill claims that the studio got the cars from Pontiac for $1 apiece, but Pontiac often gave the studio vehicles that had already been damaged from a train derailment. The Pontiac's nose was eventually extended slightly. Glen Larson wanted the talking muscle car to have a heartbeat and asked Scheffe to design a beam of light like the Cylons had in Battlestar Galactica to be used on the front of the vehicle. A mock up dashboard was used on a sound stage for closeups of the voice box or other buttons. Spare cars were always on hand, and Universal eventually did all of the modifications that were needed. The hero car was the only vehicle that contained the intricate dashboard. Stuntman Jack Gill says KITT's ride height was dropped 1.5 inches (4 cm) from a stock Trans Am. The nose and dashboard of the car were designed by design consultant Michael Scheffe.
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The car used as KITT in the series was a customized 1982 Pontiac Firebird Trans Am, that cost US$100,000 to build (equivalent to about $266,000 in 2018). Basehart's voice, however, is heard throughout the series, narrating over the intro and outro.
Richard Basehart as Wilton Knight, the founder of FLAG, who dies in the pilot episode.Peter Parros as Reginald Cornelius III aka RC3 (Season 4), driver of the FLAG mobile unit and occasional sideman for Michael and KITT.The connection between the two was never established in any installments. The character was written out when Patricia McPherson returned. Rebecca Holden as April Curtis (Season 2), chief technician for KITT.The character was dropped after the first season, but due to strong fan reaction and lobbying by Hasselhoff and Mulhare, she was returned for the third season and remained through the end of the series. Bonnie Barstow (Seasons 1, 3–4), KITT's chief technician and romantic tension for Michael. He was also the spokesman for FLAG whenever it came under scrutiny. Edward Mulhare as Devon Miles, the leader of FLAG, who appeared in every episode to provide mission details to Knight and KITT.Elsewhere, requested not to be credited for his role as KITT's voice. Daniels, who simultaneously starred on St. William Daniels as the voice of KITT, or Knight Industries Two Thousand, the autonomous, artificially intelligent car, with whom Michael Knight is partnered.Hasselhoff also played Garthe Knight, Wilton Knight's estranged son and a criminal mastermind who drives Goliath, a Peterbilt 352 Pacemaker semi-truck armed with rockets, and protected by KITT's Molecular Bonded Shell. With his new identity, "Michael Knight", Long is provided with high tech crime-fighting equipment, most notably the car named KITT.
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Wilton Knight, creator of Knight Industries and founder of FLAG, directs his doctors to save Long's life and reconstruct his face.
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The other half of this pilot program is the Knight Industries Two Thousand (KITT), a heavily modified, technologically advanced Pontiac Firebird Trans Am with numerous features, including an extremely durable shell and frame, controlled by a computer with artificial intelligence. Wilton selects Michael to be the primary field agent in the pilot program of his public justice organization, the Foundation for Law and Government (FLAG). Self-made billionaire Wilton Knight rescues police Detective Lieutenant Michael Arthur Long after a near fatal shot to the face, giving him a new identity (by plastic surgery) and a new name: Michael Knight.