The production's ambitious opening battle immediately ran into technical and human disaster. The sequence had to be mounted twice because a fault in the light meter caused the first two attempts to be underexposed, effectively making the expensive footage unusable. Repeating a large medieval battle in full armor, with extras, horses, weapons, and location logistics, was a costly setback for a film being made on a comparatively modest budget.
The strain was compounded when the original director of photography, Tony Pierce-Roberts, suffered a nervous breakdown and was replaced by Alex Thomson. Heavy rainfall in Ireland then repeatedly delayed filming, turning the production into a logistical battle against both equipment failure and the weather. Thomson ultimately completed the cinematography, earning Excalibur an Academy Award nomination for Best Cinematography, but the polished, luminous look of the finished film concealed how close the early shoot came to collapsing under technical and personal pressure.
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