Coolie/Production

Production

Development

During the filming for Master in late 2019, it was reported that director Lokesh Kanagaraj had met Rajinikanth at his residence in Chennai and narrated a script that impressed the actor. The project which would have been Rajinikanth's 169th film, was reported to be funded by Raaj Kamal Films International as Lokesh was already signed by the studio. Production was reportedly set to begin in April 2020, but it was delayed due to the COVID-19 pandemic and the actor's commitments to Annaatthe (2021). Though some reports suggested that the project was shelved due to Rajinikanth stating that he would be entering into politics and reports stating that he would enter after completing Annaatthe, others said this was not true. In August 2020, Lokesh neither confirmed nor denied the project, stating that announcing such a project officially was the producer's call. The following month, Lokesh announced a different project with Kamal Haasan, which eventually became Vikram (2022). There would be no development afterwards, and Rajinikanth's 169th film went on to become Jailer (2023) directed by Nelson Dilipkumar.

In April 2023, reports of a potential collaboration between Lokesh and Rajinikanth resurfaced, and the former conducted a photoshoot with Rajinikanth, the following month. Subsequently, Mysskin and Babu Antony, who starred in Lokesh's directorial Leo (2023) indicated on the possibility between their collaboration. That July, Lokesh confirmed the project which would be tentatively titled Thalaivar 171. On 11 September, Sun Pictures officially announced the venture through their social media platforms. The project signifies Rajinikanth's maiden collaboration with Lokesh and fifth with the production house after Enthiran (2010), Petta (2019), Annaatthe and Jailer. Lokesh and Rajinikanth would reportedly receive ₹60 crore and ₹180 crore for their remuneration respectively.

The film's official title Coolie was announced on 22 April 2024. Lokesh stated that the film would be a standalone film, separate from the Lokesh Cinematic Universe (LCU), and does not revolve around drugs, unlike his previous films, but instead focuses on gold smuggling.

Pre-production

In an interaction with Baradwaj Rangan, Lokesh stated that the script was written in 2015, when he worked on the post-production of Maanagaram (2017). He further added that, while it was written for one of his friends, after Rajinikanth showed interested in the script, he had to tweak the storyline to suit the actor. Lokesh then worked on the newly modified script in late November 2023. Rathna Kumar, a frequent writer of Lokesh's films, was unable to commit to the project due to scheduling conflicts. Subsequently, Lokesh co-wrote the film's script with Chandhru Anbazhagan, whom he previously worked with on Maanagaram. Rajinikanth was reportedly dissatisfied with the new script and suggested a few changes to Lokesh, which included reducing the violence. It took six months to complete the first half's script.

In late-October 2023, Manoj Paramahamsa was announced as cinematographer. However, he was replaced with Girish Gangadharan, in his second collaboration with Lokesh after Vikram. Anirudh Ravichander would score the music, in his fourth consecutive film with the director. Lokesh further continued to retain most of his norm crew technicians including stunt choreography duo Anbariv, editor Philomin Raj, costume designer Praveen Raja and production designer N. Sathees Kumar.

Lokesh stated that instead of filming with a standard camera and later converting it into IMAX-enhanced formats, they would be filming with an IMAX-certified camera, thus making it as the first time to do so in Tamil cinema. He also planned to use de-aging technology, a technique which Lokesh previously did for Kamal Haasan in Vikram, for showcasing the younger version of Rajinikanth. The team shot and completed filming for the promotional teaser by 9 April 2024. The film was initially intended to begin production in March 2024, but was delayed to June after a grand set which was constructed for the film's first schedule was not finished in time.

Casting

For his character, Rajinikanth would sport a grey-shaded hairstyle and beard, reminiscent of his look in Kaala (2018). Lokesh stated that, he wanted to bring the negative shade of Rajinikanth, which he did in his earlier films. Sandy, during an event in March 2024, announced his involvement in the film, reuniting with Lokesh after dance choreographing in Vikram and acting in Leo. However, he did not specify whether he would be dance choreographing or acting. Fahadh Faasil was approached to play a prominent role but declined it due to scheduling conflicts.

In July 2024, Nagarjuna was confirmed to play the antagonist. The film would mark his eighth Tamil film, and also his first collaboration with Rajinikanth and Lokesh. Describing his working experience, Nagarjuna was appreciative of his "[Gen Z] kind of film making I see in his characters and screenplay" and found that playing the role was "very liberating". The involvement of Sathyaraj was confirmed in May 2024. He would reunite with Rajinikanth after a hiatus of thirty-eight years since Mr. Bharath (1986).

Malayalam actor Soubin Shahir was cast in a pivotal role, thereby making his Tamil film debut. Kannada actor Upendra joined the film's cast in August 2024. He would make a return to Tamil cinema after Satyam (2008). Upendra stated it as a "dream come true" moment on working with Rajinikanth which was "long overdue". He further added that his role would not be an antagonist. Shruti Haasan, who previously starred with Lokesh in her music video "Inimel", was reported to play a pivotal role in the film. She confirmed her participation in the film via her Instagram story, which she deleted later, until her involvement was confirmed by the producers in late-August.

Reba Monica John was also involved in the Hyderabad schedule, although her participation was not confirmed until early December 2024. Mahendran was reported to be a part of the cast, owing to his presence in the same schedule in Hyderabad. In October 2024, Pinkvilla reported that Aamir Khan was cast for a cameo appearance in the film, while his involvement was confirmed only after his presence at the Jaipur schedule in December. Junior MGR joined the cast in late December and shed 23 kilograms for his role.

Filming

Principal photography was intended to begin with the first schedule on 10 June 2024, but the pre-production delays deferred its commencement. Filming ultimately began with the first schedule on 5 July at Ramoji Film City in Hyderabad. With around 12 days of filming, the schedule was completed by 18 July. The concurrent schedule began in late-August at Visakhapatnam, Andhra Pradesh, where the team shot major portions at the Vizag Fishing Harbour during this schedule. On 14 September, filming was halted due to a fire that erupted near the sets of the film from one of the containers at the harbour.

An Onam celebration was held at the film's sets on 15 September, with the makers sharing a footage of the team dancing to "Manasilaayo" from Rajinikanth's Vettaiyan (2024). During this schedule, an action sequence featuring Nagarjuna was leaked to social media platforms, which led to Lokesh requesting people not to share the leaked footage. The schedule ended in early October. Following that, Rajinikanth took a hiatus from filming due to health issues. He was expected to resume filming on 16 October, but instead did so a week later. The extended schedule took place in Chennai for a month, featuring Rajinikanth and other principal characters, where major action sequences being shot and a grand set was erected at the Adityaram Studios for the schedule.

After the Chennai schedule being completed, Rajinikanth and his team left to Jaipur for filming primary sequences. The schedule began on 10 December, with sequences featuring Rajinikanth, Upendra and Khan being shot. This schedule was completed by early January. Rajinikanth further revealed that 70 percent of the film had been shot, with the concurrent schedule to take place from 13–28 January.