Akshay Kumar asked director Anil Sharma to give a disabled fan of his a role in the movie. The fan, Puran Chauhan, who lost his leg in a roadside accident at the age of five, was given a small part.
Akshay Kumar was ready to opt out of the film if he had to mouth anti-Pakistani lines - he didn't want to hurt the feelings of his Pakistani fans. He rejoined the cast when his lines were rewritten.
Five ships were used for the starting scene and sailed from Vishakapatnam, with shooting happening as far as 200 km from land. Quite a few of the crew were noted to have gotten sea sick.
The name of the movie is based on the famous Indian patriotic song "Kar chale hum fida jaan-o-tan saathiyon. Ab tumhare hawale watan sathiyon" from the movie Haqeeqat (1964). The movie also has a title track based on the same song. The lines "Kar chale hum fida jaan-o-tan saathiyon. Ab tumhare hawale watan sathiyon" mean "We are sacrificing our lives and bodies, friends. Now the country is in your hands, friends".
The scene where sea water gushes into the ship after being torpedoed, was shot inside the Indian Navy's "Damage Control Simulator" at the land base INS Shivaji.
Bobby Deol plays a dual role of a father and son earlier the father's role was to be played by Shah Rukh Khan who later opted out and Deol played both the roles.
The title song in the film is the longest of any song in all Hindi films. The length of this iconic song is 20 minutes and the song is featured in 3 installments in the film.
Ameesha Patel was signed for the film but dropped by Anil Sharma at the last hour .
The song "Kurthi Mal Mal Di" was sampled from the song "DCS Express" by DCS from the album Extra Hot 8 Bhangra Remixes. Jagjit Singh also sang a version of the traditional song titled " Dhai Din Na Jawani Naal Chaldi".
Anil Sharma wanted Suresh Oberoi for a role in the film. Anil considered Suresh a good luck charm in his films. Oberoi declined for unknown reasons.
Ajay Devgan was offered the film he was to play the role of Bobby Deol's father who is an Indian Naval Officer but declined it.
First film to star Amitabh and Govind Namdeo though there worked in Zamaanat which never released.