Pre-production Director
Gautham Vasudev Menon expressed his interest to work with
Suriya again after the success of
Kaakha Kaakha (2003). In early 2005, the pair got together for a film tentatively titled
Chennaiyil Oru Mazhaikaalam which featured
Asin in the lead role and
Daniel Balaji in a supporting role. However, after a photo shoot, the film was delayed and then subsequently called off, with Menon later going on to direct the
Kamal Haasan-starrer
Vettaiyaadu Vilaiyaadu and
Sarathkumar-starrer
Pachaikili Muthucharam. In mid-2006, Menon planned a script for Suriya, which would be produced under his newly launched Photon Film Factory, and he expressed that the film will not be a sequel to
Kaakha Kaakha, but a romantic thriller film with titles such as
Naan Thaan and
Udal Porul Aavi were considered. The film was speculated to be made on a budget of , becoming the expensive film of Suriya in that period, and
V. Ravichandran of Aascar Films acquired the rights of distribution on a first copy basis. In a turn of events, Menon dropped the idea of producing the film due to budget escalations, and this prompted Ravichandran to acquire the production rights.
Development In late November 2006, Menon announced the title of the film as
Vaaranam Aayiram, title derived from "
Nachiyar Tirumoli" with the literal meaning of "the strength of a thousand elephants". Menon has described the film as "autobiographical and a very personal story and if people didn't know, that 70% of this [the film] is from my life".
Casting Menon stated that Suriya would play dual roles of a 21-year-old Suriya and his father Krishnan. Suriya lost weight without using capsules and prepared a
six-pack for the film through an eight-month fitness regime. For Surya's father Krishnan's role, Menon initially approached
Mohanlal and
Nana Patekar, but it did not work out as there was an issue about how they would portray the character's younger age (his twenties) in the flashback scenes, thus Suriya expressed interest in portraying the character himself.
Deepika Padukone was first approached for the lead actress role, but she backed out to be part of the Hindi film
Om Shanti Om. Soon after,
Andrea Jeremiah was confirmed as the heroine after working with the director in
Pachaikili Muthucharam, but was dropped from the film for unknown reasons. The producers then announced the film with
Ramya, who was making her comeback to Tamil films, and
Genelia D'Souza in the lead roles. Ramya was credited by her real name, Divya Spandana. Soon after the start of the shoot, D'Souza decided to walk out, after Menon refused to pay the hefty salary that she was demanding and receiving in Telugu films, allowing
Sameera Reddy to act in her first Tamil film.
Simran, who acted alongside Suriya in his debut film
Nerrukku Ner (1997), was selected to portray the mother of Suriya, after
Tabu had rejected the role. Menon's norm technicians: cinematographer
R. Rathnavelu, editor
Anthony Gonsalvez, art director
Rajeevan and music composer
Harris Jayaraj, were part of this film.
Filming served as shooting spot in
"Adiye Kolluthe" song Principal photography commenced on 24 November 2006 in
Chennai. In April 2007, it was announced that a 10-day shoot in Afghanistan would be followed by shooting in Malaysia, Russia and the United States, thus
Vaaranam Aayiram was the first Tamil film being shot in Afghanistan. However, the film only completed a shoot at the
University of California in
Berkeley and shooting was not held in Afghanistan. In November 2007, when filming in the United States was still ongoing, Menon decided to send the reels back to Chennai. Two of the production managers were assigned the task of bringing the reels to the producer's office; however, the pair decided to stay in Singapore for a couple of days before returning to Chennai. Following their arrival in Chennai, it was discovered that the reels went missing in the hotel they stayed at in Singapore, and a search by the police proved unsuccessful. The whole crew was in a bind as the reels held fight scenes, songs and other scenes worth $500,000 ( crore). Soon after, the reels were found with the Singapore airport authorities. The team later shot few schedules in Chennai during January 2008 and was completed within a month. The team further shot sequences in
Kashmir and
Delhi, and continued intermittently so that Suriya could work on his commitments for
Ayan. Filming ended in August 2008, after one year of production. == Music ==