The fight on the Great Wall was shot in seven days. It was originally planed to be shot in 20 days but the Chinese government would only allow for seven days for tourism purposes. Those seven days were extremely busy; Akshay Kumar, who usually shoots for only 10 hours a day, had to shoot for 18 hours in chilly conditions on the Wall.
The film's teaser poster (Akshay Kumar in a Chinese robe, carrying a sword-kebab) was designed by Rohan Sippy. Sippy went to Kumar with this poster and said he wanted to make a film with him, centering on this concept. Sippy also developed the fundamental plot from this poster in about three months.
Several shows were cancelled in Nepal due to the protests from students, archeologists, Buddhist monks, researchers, and youth groups. Protests included threats by Buddhists to burn cinemas that screened the film, and racial slurs like "Dhoti" hurled at the Indian embassy in Kathmandu.