Meanwhile, Tony Award-winning Broadway singer Sara Ramirez (Torres) suggested using tracks from the series' history, like Chasing Cars and The Fray's How to Save a Life, which became a top 10 hit worldwide after featuring in season two.
"We did this gig for the execs - gave then lunch and made them feel like they were in some cool cafe - then did a full-on presentation where Shonda explained the story," says Kevin. "At certain points, we all sang. It was nerve-wracking, but it worked."
It wasn't until filming started that everyone realised the logistical challenges involved, like everything taking three times as long to film.
"It was a lot of hard work," says Justin Chambers, who plays Dr Alex Karev. "They really took a chance on that episode and we have to give credit to Shonda and the show for that. To be this far into the series and go, 'let's try something different'.
"And they're inspired by the musical stuff, which is really popular right now. There are lots of talented kids who can sing and dance and that's fun to see - a lot of people didn't know Sara is such a brilliant singer."
LOWDOWN
What: Grey's Anatomy, musical episode
Where and when: Tuesday, 8.30pm.
- TimeOut