Behind the Scenes: Jim Caviezel’s Harrowing Experience Filming Passion of the Christ

SANTA MONICA, Calif. — Filming “The Passion of the Christ” in 2004 was not only a meticulous endeavor in religious cinema but also a perilous experience for lead actor Jim Caviezel, who faced numerous on-set accidents. Perhaps the most frightening incident occurred when he was struck by lightning during filming.

Caviezel, who later starred in “Sound of Freedom” (2023), underwent an intense physical and emotional trial to bring the character of Jesus to life. One of the most dramatic moments happened while shooting the Sermon on the Mount scene. As he climbed unstable terrain, dark clouds began to gather above the set.

“As I ascended the mountain, I felt an ominous premonition just five seconds before the strike,” Caviezel recalled in an interview with a Polish journalist. “Then, suddenly, the lightning hit me,” he stated. Director Mel Gibson noted the event when he saw Caviezel’s hair standing on end from the electrical discharge during the last take.

Quickly moving to assist him, first assistant director Jan Michelini also became a victim of the storm when another lightning bolt struck him. Miraculously, both men survived the incident.

In an interview with Fox News in July 2023, Caviezel revealed that the event had more serious repercussions than initially thought. The lightning strike resulted in a heart condition that necessitated two surgeries, including one open-heart procedure. “It was resolved in 2014,” he explained.

However, this wasn’t the only incident that Caviezel faced while portraying Jesus of Nazareth. Gibson aimed to depict the suffering of Christ with extreme realism, leading to particularly demanding scenes, such as the flagellation. During this sequence, Caviezel was struck hard by one of the actors portraying a Roman soldier. Despite wearing a protective wooden pad, the whip managed to penetrate it.

“I couldn’t breathe. The pain was unbearable. I thought it would only happen once, but within minutes, it struck me again,” Caviezel recounted. The aftermath was a 14-inch scar on his back from the real lash that even appeared in behind-the-scenes footage. “It’s so painful that it shocks your system,” he described.

In addition to these injuries, Caviezel suffered from a lung infection, hypothermia due to strong winds during the crucifixion scenes, and severe bruising from the weight of the chains he was required to carry. During the Way of the Cross, the nearly 150-pound cross he bore slipped and fell directly on him. “It crushed my head like a melon. Blood was pouring from my mouth. Some of that blood was fake, and some was real,” he said in production material.

Furthermore, he bit his tongue and cheek when the cross fell unexpectedly on his head. Following its release in 2004, “The Passion of the Christ” became a global phenomenon, grossing $612 million worldwide, making it the highest-grossing independent film in history. The film is currently available on Netflix and is a recurring feature during Holy Week.

Two decades after the original’s premiere, Caviezel is preparing to reprise his role as Jesus in a sequel directed once more by Gibson. Filming is set to begin in August 2025, with confirmed locations including Cinecittà Studios in Rome and various cities in southern Italy, such as Matera, Gravina, and Altamura. The project, co-written by Gibson and Randall Wallace, has been in development for several years.

In a 2020 interview with National Catholic Register, Gibson hinted that the story would not follow a linear narrative but would explore supernatural dimensions, including hell and the fall of angels.