Production of the computer graphics imagery in the movie was convoluted and problematic. Uwe Boll claims he had to fire several different CGI providers, who outsourced their jobs to lower-quality providers, who worked for less money.
During production, Uwe Boll sponsored a charity visit to the set. Guests got to see behind-the-scenes work, and proceeds were donated to a children's hospital. Reportedly, Ray Liotta was extremely upset by it. In future interviews, he talked about how "crazy" Boll was for allowing so many spectators onto the set.
John Gajdecki had trouble filming many visual effects shots, especially scenes with outdoor "greenscreens". Jan Kruse left the project, due to conflict with Gajdecki, who was eventually fired, and replaced by Doug Oddy.
While filming an outdoor fight scene, Burt Reynolds grew overheated in his armored costume, became unconscious, and fell from the platform, on which the duel was being filmed. Reynolds claims this was the only time in his career that he had to miss a day of filming, due to sickness or injury.
Kevin Costner was offered the lead role. Uwe Boll claims Costner wasn't interested in filming a large-scale action film, and instead offered Boll the opportunity to direct the project he was working on at the time, Mr. Brooks (2007). Boll turned it down.
Uwe Boll claims that the two hours and thirty-six-minute Director's Cut of the film is not, in fact, the complete version of the film. Boll claims that an unreleased, three-hour version of the movie was created, that featured more scenes of character development.
A day of filming was lost due to heavy fog. Some of the forest terrain and mountaintops could only be accessed via helicopter, and on a particular foggy day, Uwe Boll and part of his crew were literally stranded on a mountain for over two hours, because the helicopter wouldn't take off.
The trivia item below may give away important plot points.
Burt Reynolds extensively re-wrote and edited the dialogue for his death scene, creating friction with Script Supervisor Ingrid Kenning. Reynolds had never played a character who died in a film, and was adamant that the scene be something special.