Gunga Din was given the greenlight and George Stevens launched out on the waters of production despite being not exactly satisfied with the script. But he was not overly concerned. He had his two scripters along to sand down the rough spots and paper over the cracks.
Stevens was used to flying by the seat of his pants. He had cut his teeth at the Hal Roach studio as a cameraman. First with the action filled adventures of Rex the Wonder Horse, and then later adding gag man to his lenser chores on Laurel and Hardy shorts. These experiences had helped him on his features thus far and would bring solid gold to his production of Gunga Din.
So the following will be part chronology and part discussion of how problems arose and how they were solved.
Casting had been a long process, stretching back to when Howard Hawks was in charge.
Before a script was in place RKO looked to finagle a deal to trade with MGM for the services of Clark Gable, Spencer Tracy and Robert Montgomery. That was 1936, two years later after many more names (and combinations) were considered along the way they landed their dream cast of Cary Grant, Douglas Fairbanks Jr., and Victor McLaglen – the term of their contracts – to run from 6/1/1938 to 9/3/1938.
The million dollar production did not kick off until the last week of June with work on interiors at the studio (stage 14 the punch bowl scene). Work was ongoing constructing the outdoor sets up in Lone Pine CA (in the shadow of Mt Whitney, the surrounding Sierras dubbing in for the Khyber Pass) and on the RKO ranch in Encino.
All was ready when the caravan of technicians set out on the morning of July 13, with the coterie of performers following three and a half hours later.
They had no sooner settled in to the tent city prepared for them when a fire broke out on the outdoor set of the village (called Tantrapur in the film). Despite everyone’s efforts five buildings and many props were destroyed (Lloyd’s of London was on the hook for $5000, or $91,000 in 2019 dollars).
Fortunately the village set was not the only one they had built, two more were available- the Kali-Thuggee temple and the British army canton.
Stevens met this first obstacle the very next day by setting to work on the canton set. With his writers in tow he put together a scene with the army parade ground as the backdrop. It was a great example of making lemonade from a bad situation. While the extras were put through the paces of learning their drill, Sam Jaffe (Din) and Cary Grant enacted a scene that gives the viewer crucial information about these characters. They were getting excellent value for the money spent.
And nothing makes a studio happier than when they can see the money they are spending reflected back to them on the screen.