Adventures of Captain Marvel was budgeted at $135,553, although the final
negative cost was $145,588 (a $10,035, or 7.4%, overspend). It was filmed between December 23, 1940, and January 30, 1941, under the working title
Captain Marvel. Undaunted, Republic's completed script was reworked with various changes; it now had an original masked hero, the Copperhead, standing in for Superman, subsequently becoming the
Mysterious Doctor Satan serial. The studio then approached Fawcett Comics about filming their most popular superhero, and they agreed. Director
William Witney, however, was skeptical about trying to adapt Captain Marvel after the problems encountered with Superman. In spite of this,
Adventures of Captain Marvel became the first superhero film adaptation of a
comic book character. National attempted legal action to prevent Republic from developing their arch rival's most successful character, citing Republic's failure at adapting a Superman serial. Their attempt was unsuccessful, however, and Captain Marvel went into production. Writing in his autobiography of the period, William Witney revealed that in his court
deposition he had claimed that both Superman and Captain Marvel were derivatives of
Popeye. which they ultimately wound up purchasing, adding a final chapter to the Fawcett/DC saga. The opening military scenes in the serial were reused footage lifted from Republic's 1938 film
Storm Over Bengal.
Casting Republic cast Frank Coghlan as Billy Batson due to his physical resemblance to the character. There was, however, some criticism that Tom Tyler did not sufficiently resemble the "beefy, baby-faced" Captain Marvel. Tyler was described as clumsy, knocking over props with his "lanky arms". Punches in fight scenes would sometimes connect.
Special effects Republic's flying effects, under the direction of
Howard and Theodore Lydecker, were performed using a dummy that was slightly larger than life (at 7 feet tall) and made of papier-mache so that it weighed only 15 lbs. The uniform was made of thin silk and cotton jersey. The technique had been developed in their earlier serial
Darkest Africa (
1936) and was later used again in their "rocket man" serials (
King of the Rocket Men,
Radar Men from the Moon,
Zombies of the Stratosphere, and
Commando Cody: Sky Marshal of the Universe) released from
1949 through
1953. By contrast, the lower-budget
Columbia Pictures Superman serials, which eventually appeared in the late 1940s, used cartoon animation sequences to represent Superman's flying scenes; The effect is considered vastly inferior to those for Republic's live-action sequences in
Captain Marvel. Columbia produced the cheapest serials of the era, and producer
Sam Katzman was notorious for cutting costs to the bone. The decision to use cartoon animation for Superman's flying is puzzling, since these scenes took longer to make and cost more than a mechanical effect as Republic used.
Costume One of Captain Marvel's
tunics later appeared as the costume of a member of the Kryptonian science council in the first episode of
The Adventures of Superman television series, filmed in 1951. The lightning bolt on the tunic is partially concealed by means of an oversized collar around the actor's neck. After the usage in the
Superman TV series, two Captain Marvel tunics were worn by actors in early episodes of the pioneering U. S.
science fiction TV series
Space Patrol. Early into the series, those Marvel tunics were replaced by custom-made shirts. At the
Museum of Pop Culture in Seattle, Washington, one of the remaining Captain Marvel tunics is on public display. ==Release==