Question: In the 90's TV version, there's an extra scene where Tyler gives Andy a knife and says "A good soldier is always prepared" at the beginning. Later, they trade the knife back and forth. I could swear at the end of the TV version, when Tyler hands Andy the knife and he cuts Chucky's hand off, Tyler screamed "A good soldier is always prepared!" But that isn't on the "Deleted TV Scenes" on the new Shout Factory Blu-Ray. Anyone else remember that extra bit of dialogue, or am I misremembering?
Question: At the beginning of the movie, the entire Good Guy factory is completely covered in dust and cobwebs because of not being used in eight years. What caused the factory to close for such a long time? Nobody believed Andy when he said that his Good Guy doll was possessed by Chucky. And even though Andy said Chucky was responsible for so many murders in his doll form, people most likely wrote it off as a child's overactive imagination and that wouldn't be enough to close down the factory.
Question: Why didn't Alex Vincent reprise his role as Andy?
Answer: The film makers wanted to make Andy older in the film so he could have a love interest and be in military school. At the time Alex was only 9, but they wanted Andy to be 16. So they recast the part.
Answer: To add to the other answer, the writers and producers felt that after two movies they had gone as far with child Andy as they possibly could have. They felt it would be too redundant to have a third film with Andy as a kid being pursued by Chucky. So they set this film years later when Andy was a teenager.
Question: In Child's Play 1,2 and 3, we learn that Chucky bleeds once he is human, so why would not the cops notice blood on the ground or wherever Chucky met his demise, test the blood and verify that it belongs to Charles Lee Ray, hence confirming Andy's and his mother's story?
Answer: The police would be very skeptical that a serial killer could transfer his soul into a child's toy. Even though in the first movie Detective Logan and his partner finally believed it, in the second movie it was stated that the police denied everything. Even though several people did survive Chucky's rampage, it could easily be chalked up to an overactive imagination brought on by severe psychological trauma.
Question: When Chucky is loading the guns with real ammo instead of paint, why would a military school store or even use live rounds?
Answer: Military schools usually have gun ranges, so they would have live ammunition for that.
Answer: They would have live rounds for use on the ranges. The real issue is that they'd also have it drummed into them to personally check the ammo of any weapon handed to them so the shooting should never have happened.
Answer: The public believes that the Good Guy doll that committed the murders had simply malfunctioned, which caused great negative publicity for the company. The public does not believe Andy or his mother's claims that the doll was possessed by a serial killer and was actually alive. In Child's Play 2 the company finds and reassembles the doll to prove to shareholders that the Good Guy doll is safe. This backfires and the doll is re-possessed, which leads to additional murders in that film crippling the company for 8 years.