There was going to be a Ghost that would want to cut off luigi head but was deem to gory by Nintendo.
The ghost was mention in Nintendo Magazine.
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http://www.n-sider.com/contentview.php?contentid=261
The game was also consider to be on the N64 but ultimately decided to be on the gamecube.
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Originaly,the developers wanted to make mario-theme levels and a cave-like basements but was abandoned for the mansion.
Qoute:
Kanno: Mr. Konno was making the maps already from some of his original plans. There was a prarie and desert level when it was tentatively using the Mario theme. We had to leave those out of course when the mansion idea took precedence.
Konno: The composition that there would be three storie and a basement was decided early in development. The following designs became a matter of how do we keep the mansion varied. Since we were going with the western style; there is a huge stair case in the lobby, a bathroom in each floor, a training room, a music room, etc.
Kanno: We were very conscious of each space.
Konno: We also came up with the idea of an underground cave to sort of extend the geographical environment. The early designs also had a sort of RPG system which upgraded the stage after certain actions, we sort of decided to work more with the cleaning machine (vacuum). I wanted this to be a game you could play repeatedly.