Production
The entire film was shot at the Barrandov Studios in Prague, Czech Republic.
The film includes a great deal of jousting footage. The initial scene of the two knights jousting is actually footage of Heath Ledger's stunt double in an accident. During filming of a later scene in the movie, the lance of the stunt double's opponent moved off target and hit him in the head. The double fell to the ground unconscious. In another incident, Heath Ledger knocked out one of director Brian Helgeland's front teeth with a broomstick when the two were demonstrating a jousting move. It took several months for Helgeland's mouth to heal enough to repair the damage.
Plenty of effort was expended creating lances that would convincingly explode upon impact without injuring the stunt riders. The body of each lance was scored so it would break easily, and the tips were made of balsa wood. Each was also hollowed out, with the holes filled with balsa splinters and uncooked linguine. Jousting armour was made by Rod Vass and his company Armordillo Ltd. using a unique sprayed polyurethane system that they invented for the film Gladiator. On screen it is almost impossible to distinguish between the polyurethane stunt armour and steel armour, much of which was also made by Armordillo. Heath Ledger's armour was originally made in steel along with three polyurethane stunt replicas.
Read more about this topic: A Knight's Tale
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