Exclusive: Mel Gibson's Apocalyto Now

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In fact, says veteran production designer Tom Sanders, Apocalypto "is the hardest show I've ever worked on." Stacks of archaeology books and magazines are strewn about a massive warehouse in Veracruz, where an army of costume and makeup artisans from Mexico and Italy are painstakingly re-creating feathers of the nearly extinct quetzal for royal headdresses and long, looping earlobe extensions for warriors. (Because those prostheses are difficult to apply, the actors must wear them for days on end, which rather spooks fellow guests at the Fiesta Americana Hotel.) This month Gibson starts filming at a sprawling and meticulously appointed city of Maya pyramids and markets that Sanders' crew spent six months building outside Veracruz. It all suggests a Titanic-size budget, but Gibson will say only that his production company, Icon, is spending less than $50 million. (The Passion cost $30 million.)

Given that controversy hit his last film months before it even finished production, Gibson has been careful to build Mesoamerican goodwill for Apocalypto: two-thirds of the cast and crew are Mexican, and Gibson has donated $1 million to communities in Veracruz state affected by Hurricane Stan last year. Mexican cast members like Mayra Sérbulo, 30, a Zapotec Indian who plays a villager, say they expect some criticism of the film from Mexican nationalists (who also tore into Salma Hayek's Frida), especially since it touches on the raw issue of human sacrifice, which scholars don't believe was a prevalent Maya practice until the post-classic period, after A.D. 900, when fiercer influences like the Toltecs and Aztecs arrived. It is in that period, not coincidentally, that Apocalypto is set. "But I'm frankly surprised and excited that someone is making a film about an indigenous Mexican culture that most Mexicans don't even know all that well," says Sérbulo. "I feel valued by this movie."

Gibson nonetheless is a lightning rod--pro-Mel and anti-Mel blogs abound on the Internet--and he knows that even non-Mexican detractors will ask why, if he's so morbidly fascinated with the bloody deeds of Jewish Pharisees and Maya priests, he doesn't hold a mirror to his own church and film the Spanish Inquisition. Gibson won't say that's a future plan, but he nods and agrees that "there are monsters in every culture."

The more immediate question is whether Apocalypto can repeat The Passion's success. After all, devout Christians willing to sit through Latin and Aramaic dialogue to see Christ crucified vastly outnumber Maya scholars. Gibson seems certain that the film's "kinetic energy" will make Maya language and culture "cool" enough to attract a crowd. Maya prophecy says the current world, which began 5,000 years ago, will end in 2012. So, even if Apocalypto flops, Gibson will at least have given the Maya one last chance to get the word out.