Sanjay Khan’s house was mortgaged, cars sold after Tipu Sultan fire accident, recalls son Zayed Khan: ‘His skin was melting on the hospital sheet, couldn’t recognise’

In a deeply emotional revelation, Bollywood actor Zayed Khan has opened up about the darkest chapter in his family’s life — the 1989 fire that almost took the life of his father, veteran actor-producer Sanjay Khan. The disaster on the set of The Sword of Tipu Sultan not only left Sanjay Khan with life-threatening injuries but also plunged the Khan family into financial and emotional turmoil.

The Day That Changed Their Lives

On February 8, 1989, a devastating fire erupted at Mysore’s Premier Studios, where the lavish sets of Tipu Sultan stood. An electrical short circuit sparked the blaze, and due to highly flammable materials and inadequate safety measures, it quickly turned deadly. Over 60 people lost their lives, and more than 100 were injured. It remains one of the worst on-set tragedies in Indian television history.

Sanjay Khan, who was starring in, directing, and producing the show, became trapped amid the flames. By the time help reached him, he had sustained burns on more than 65% of his body. What followed was a long, painful recovery — including 13 months in the hospital and 73 surgeries.

Zayed’s Painful Memory

Zayed Khan, then a child, visited his father in the hospital. “I couldn’t recognise him. His skin was melting onto the hospital sheet,” he recalled, the trauma still vivid in his voice. “He was unconscious and connected to tubes. That image stayed with me forever.”

The fire did more than harm Sanjay physically. It also left the family emotionally shaken and financially burdened. “We had to sell our cars. The house was mortgaged. Everything was falling apart,” Zayed said. “But even in that state, my father didn’t give up.”

How the Khan Family Held On

The entire family came together during that dark period. Zayed credits his mother, Zarine Khan, for holding the family strong. “She never let us feel like the world was ending. She managed the hospital visits, kept us kids going, and dealt with the financial pressure all at once,” he explained.

Close friends from the film industry stepped in with support. Still, most of the recovery — emotionally and financially — was handled by the family themselves. They faced uncertainty daily, yet continued to persevere.

Sanjay Khan’s Unbreakable Spirit

Sanjay Khan didn’t let the accident define him. After countless surgeries and more than a year of rehabilitation, he returned to the set to finish The Sword of Tipu Sultan. His resilience stunned everyone. “He didn’t just recover — he came back stronger and more determined,” said Zayed.

In his memoir The Best Mistakes of My Life, Sanjay detailed the unbearable pain and the hallucinations he experienced. The scars remained, both inside and out. Yet he chose to stand tall and reclaim his identity.

Zayed’s Lessons from Tragedy

Zayed says the accident shaped his understanding of strength. “Seeing my father rise from that trauma taught me that nothing is too big to overcome. If he could walk through fire — literally — and still smile, what excuse do I have to give up?”

That life-altering experience taught Zayed the importance of family, resilience, and emotional strength. The memory of that fire continues to be a reminder of how life can change in seconds — and how courage can bring you back from the edge.

A Wake-Up Call for the Industry

This horrific incident also highlighted the shocking lack of safety on Indian sets during the 1980s. There were no emergency exits, no fire extinguishers nearby, and no safety protocols. The tragedy prompted calls for stricter measures, although progress has remained slow.

Many believe the fire could have been prevented with basic precautions. Families of the deceased crew members still seek justice and recognition. While some blamed Sanjay Khan for negligence, he has consistently described it as an unfortunate accident that spiraled beyond anyone’s control.

Legacy of Strength

Today, Sanjay Khan stands as a symbol of perseverance. His journey from near-death to creative revival remains an inspiration to his family and fans alike. His children, including Zayed and designer Sussanne Khan, often speak of their father’s undying willpower.

“My father’s scars tell a story of pain, but also of strength. That’s what makes him who he is,” said Zayed. “The fire didn’t break him. It built him into something extraordinary.”