A Varanasi based Don (Sunny Deol) dreams of seeing himself on the big screen. To facilitate this mad affair, he seeks the services of Arshad Warsi and Shreyas Talpade who are playing a director and a writer respectively. Ameesha Patel plays an actress and Preity Zinta, a small-town girl and Sunny's wife, tries to emulate her.

• Sunny Deol
• Mithun Chakraborty
• Preity Zinta
• Ameesha Patel
• Arshad Warsi
• Evelyn Sharma
• Shreyas Talpade
• Sanjay Mishra
• Pankaj Tripathi
• Jaideep Ahlawat
• Mukul Dev
• Brijendra Kala
• Pankaj Jha
• Prakash Raj

Initial cast announced in 2011 included Sunny Deol, Ameesha Patel, Arshad Warsi, Tusshar Kapoor and Prakash Raj. Release was scheduled for 2012. First look poster was released in March 2012. It was inspired by a Johnny Depp photoshoot. An initial poster featuring Deol in kurta, jeans and jacket was prepared but the director wanted to give a "royal" look to Deol's character and replaced the poster. In May 2012, Hindi film website Bollywood Hungama reported that the director had approached Subhash Ghai after producer Fauzia refused to increase the film's budget by ?6 crore (US$890,000). Claims regarding the film being shelved were rejected by the film's cast and director. Ghai also denied that he was producing the film. In July of the same year, Kapoor left the project due to schedule conflicts with Shootout at Wadala and Kyaa Super Kool Hain Hum. Also Zinta was removed from the cast due to unavailability of dates on her side. Shreyas Talpade replaced Kapoor.

In April 2013, Zinta confirmed her participation in the production. She plays's the don's wife.^[10] A 45–days long shooting schedule, beginning in September 2013, was conducted in Udaipur, Rajasthan.^[11] Reportedly, in November 2013, there was a dispute between producer Mahendra Dhariwal and Deol. The latter wanted his remuneration before dubbing. Deol gave him the option that they could release the film under the banner of his production company Vijayta Films. Dharival consulted action director Tinu Verma, who advised that Deol should be paid and the project should be completed.^[12] However, shooting of a few of Zinta's scenes was delayed due to her involvement with the Indian Premier League.^[13] Kharaj Mukherjee will play the role of a police inspector. The director narrated the story to him over phone and he quickly agreed to join the project.^[14] Evelyn Sharma learnt Hindi by taking lessons for 2 hours a day. She also requested her friends to use only Hindi while conversing with her.^[15] Deol will play a double role. The project was stalled for 4 years before June 2015, when it was reported that filming would resume in July 2015. A song marathon was shot in December 2016 where 4 songs were shot together. It will be interesting to see Sunny Deol Shaking his leg on all the four songs which are choreographed by renowned choreographer Ahmed Khan. As currently stated by producer Mahendra Dhariwal the film will be one of the biggest hits of Sunny Deol as it's a very interesting story & makers are looking for a single release. Bhaiaji Superhit directed by Neeraj Pathak & produced by Metro Movies and presented by Zee Studios is scheduled for release in October 2018.^[16]

Himesh Reshammiya, Sajid-Wajid, Meet Bros, Raftaar, Sanjeev Raval and Gautam Mrinaal will compose for the film's soundtrack.^{[citation needed]}