Aishwarya’s 20kg Gold Ensemble That Triggered a 50-Man Security Detail

Delhi — When Aishwarya Rai walked onto the set of Jodhaa Akbar draped in 20 kilograms of real gold, the cameras weren’t the only thing fixed on her — 50 security guards were, too. In one of the most remarkable examples of Bollywood costume security, the filmmakers transformed the shooting floor into a heavily guarded zone to protect not just their lead star, but also the literal treasure she carried.

The year was 2008, and Ashutosh Gowariker’s historical epic was redefining production scale in Indian cinema. But few knew that behind the grandeur lay a near-military-grade protection setup. Rai’s jewellery — a majestic combination of gold, rubies, and pearls — was so valuable that the production team feared theft. The decision to employ 50 guards wasn’t cinematic flair; it was a logistical necessity.

Crafted by over 70 artisans and curated by designer Neeta Lulla, the jewellery ensemble was not just a visual treat — it was authentic, heavy, and breathtakingly expensive. For days, Aishwarya had to endure the physical strain of her opulent ensemble, all while delivering a performance that has since become one of the most iconic portrayals of a royal woman in Bollywood.

This instance of Bollywood costume security remains unmatched. While Indian cinema is no stranger to elaborate sets and costumes, never before had real gold — 20 kilos of it — become both an aesthetic element and a security liability.

The risk, however, paid off. Jodhaa Akbar became a box-office success, grossing ₹107 crore globally against a ₹45 crore budget. Critics hailed it for its visual splendour, and audiences remembered the regality — much of which was owed to Rai’s golden appearance.

More than a costume decision, this was a moment where cinematic storytelling met real-world risk management. A perfect storm of history, beauty, and bullion, guarded like state treasure.

Even today, in the annals of Indian film lore, the phrase Bollywood costume security often circles back to that very moment — when royalty wasn’t just portrayed, but protected.