The film was directed by Joseph Sargent and written by Peter Allan Fields with the story by David Victor.

Unlike the four earlier feature movies, The Spy in the Green Hat made only minimal changes to the episodes.

What was changed was the addition of some short scenes that are more violent, sexy, and disturbing than generally shown on American network television at the time.

The series theme played under the main titles was a faster tempo reworking by Nelson Riddle of Gerald Fried's third season arrangement featuring trumpets, organ and saxophone solo.

The base is run by Louis Strago, who in conjunction with former Nazi Dr. von Kronen is planning to detonate atomic bombs in the Atlantic Ocean.

The bombs will cause the Gulf Stream to divert, wreaking havoc in Europe and the United States and warming Greenland sufficiently for it to become a strategic new home for THRUSH ("THRUSHland").

In one scene, 'Fingers' Stiletto smashes what appears to be a grapefruit half into the face of his wife, played by Joan Blondell.

This is likely an homage to a similar scene between James Cagney and Mae Clark from 1931's 'The Public Enemy', in which Blondell also starred.

Tortured by Miss Diketon (who truly loves her work), Kuryakin is to be executed at a party held for Strago's immediate superior in THRUSH, Mr. Thaler.