The first cut of the film was 7 hours and 30 minutes long. Aamir Khan wore his wife's earrings for the role of Bhuvan. The movie was shot in villages of Bhuj (Gujarat). Bhuj was destroyed in an earthquake on 26th January 2001, six months after the movie was shot. The movie had the biggest number of British actors ever to be cast in a single movie in the history of Indian Cinema.

The first Bollywood production in 30 years to use synchronized sound. An Arri535 camera, brought over from Germany, was used to facilitate sync-sound recording. Most Indian films are dubbed entirely in the studio in the process known as ADR. Aamir Khan got his ears pierced so that he could actually wear earrings. In the last days of shoots, a real match between British and Indian teams was played, which the British eventually won.

Paul Blackthorne spent six months learning Hindi for his role in the movie. A lot of the crowd that we saw cheering during the match scene, were actual villagers who came every day to be a part of the film. They would sit patiently in sun the entire day while the film was shot. Lagaan has many parallels with Bhuvan Shome (1969). Amitabh Bachchan is the narrator in both the movies. The hero and heroine's name are the same, Bhuvan and Gauri. Suhasini Mulay who played the heroine in Bhuvan Shome, played the hero's mother in Lagaan. Both movies were shot in Gujarat.

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