Faced with Jordanian import restrictions on real small arms prop ammunition, the Hurt Locker's weapons and effects crew improvised — special effects artist Richard Stutsman resorted to Chinese fireworks as a surrogate gunpowder source. One night the armorer, David Fencl, was up late finishing what the production needed to pass for sniper ammunition when heat and friction ignited the makeshift materials. The explosives detonated in his face, a startling on‑set accident that left Fencl wounded and sent ripples of alarm through a production already strained by extreme heat and sparse resources. Remarkably, Fencl returned to set two days later, but the incident underscored the thin margin for safety on this shoot: an ad hoc supply chain, creative short‑cuts to skirt customs, and the kind of improvisation that can quickly turn dangerous when real pyrotechnics are involved. The accident forced a re‑examination of how the crew manufactured props under local constraints and highlighted the risks small, independent productions take when bypassing standard armory channels.
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