Following the success of
Jeans (1998),
S. Shankar chose to make a political action film, which would later become
Mudhalvan. The lead role was initially written with
Rajinikanth in mind, but he was unwilling to star in the film.
Vijay was also considered by Shankar for the role, though the actor turned the offer down. Shankar revealed that he even approached
Kamal Haasan for the film, but he was doing
Hey Ram at that time.
Arjun, who had previously collaborated with Shankar in
Gentleman (1993), was willing to offer bulk schedule dates for the film and was subsequently signed on. Shankar noted that he was interested in casting
Meena as the lead actress, but opted against doing so as the actress was working with Arjun in another film in the same period,
Rhythm (2000). Subsequently,
Manisha Koirala, who worked with Shankar in
Indian, was selected to play that role.
Raghuvaran was signed to play the chief antagonist in the film, while
Vadivelu and
Manivannan were also chosen to play other characters. Despite reports that
Shilpa Shetty was added to the cast in February 1999, it was later clarified to be untrue.
Laila, who had made her acting debut earlier in the year with
Kallazhagar, was signed on to appear in the film. Originally, her role was supposed to feature throughout the film, but Shankar shortened her character, owing to her call sheet problems. Renowned
muralist Natanam and
Kalairani were cast as Arjun's parents.
S. Sashikanth, who went on to produce films like
Tamizh Padam (2010) and
Kaaviya Thalaivan (2014), and K. R. Mathivaanan, who directed
Aridhu Aridhu (2010), worked as assistant directors. The film was jointly launched by S. Shankar and his co-director
R. Madhesh in October 1998 at an event attended by actors and technicians from the Tamil film industry, with actors Rajinikanth and Kamal Haasan being the special invitees. Production continued for several months, with reports suggesting that the film was delayed due to Manisha Koirala's unavailability though Shankar later stressed the production work demanded such delay. Parts of the film were also shot in
Bikaner,
Rajasthan while the team also shot extensively in rural
Tamil Nadu. The film's cinematographer Anand later noted that the scenes involving crowds shot on
Anna Salai,
Chennai were among the hardest and most satisfying scenes he had worked on. The song "Shakalaka Baby" was the last song to be shot, with
Sushmita Sen selected to feature in a special appearance for the song. Stunt master
Peter Hein revealed that he worked as a body double for Arjun in the scene where he had to run nude on the streets. == Themes and influences ==