Stuntman Jack Montgomery, who played a Christian cavalryman in the film, recalled in an interview the tension that existed between director Cecil B. DeMille and the dozens of stuntmen hired to do the battle scenes. The stuntmen resented what they saw as DeMille's cavalier attitude about safety, especially as several stuntmen had been injured, and several horses had been killed, because of what the stuntmen perceived as DeMille's indifference. At one point DeMille was standing on the parapets of the castle, yelling through his megaphone at the "combatants" gathered below. One of them, who had been hired for his expertise at archery, finally tired of DeMille's screaming at them, notched an arrow into his bow and fired it at DeMille's megaphone, the arrow embedding itself into the megaphone just inches from DeMille's head. DeMille quickly left the set and didn't come back for the rest of the day. For the rest of the picture, he never yelled at the stuntmen again.
Loretta Young kept it a secret that she was three months pregnant with her daughter Judy Lewis during the shoot.
A Paramount prop man, Daniel Ulrich, had his right leg crushed by the 35-ton siege tower used in the battle of Acre.
Director Cecil B. DeMille interspersed real firemen, costumed as crusaders, among the battle scene extras in order to prevent any fires from getting out of control. Firefighting equipment was also hidden under props, out of camera range but within easy reach.
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