IIRC he was asked by the director to practice for a scene so they could check the lighting and the camera angle.Is that what actually happened or are you making bits up?
Which is basically a specific type of rehearsal and not "mucking around", and is something that is utterly routine in film and tv as it costs a lot less to have the actor on the set with the lighting etc and the director/camera person there making sure the lighting is right and it looks ok than it is to do the entire scene and have everyone on set.
Or would it have been fine with you if the death had occurred when the set was full and the camera was running?
Long post. Blah. As you correctly assert you need a working gun to fire blanks. You don't fire blanks directly at people. See Brandon Lee as to why.
If you want to point a gun at people, the relevant effects can easily be added in post processing. It's already been stated that they didn't do this on rust because they wanted a 'more authentic effect'.
You don't point a blank firer at a person (certainly not within a certain distance), but pointing it at the camera that might be several meters away is still done as the risk is so low and is routine for certain shots, blanks are IIRC only normally any danger within a very short range due to the lack of mass of any of the unburned propellant, the blast pressure and the very low mass of any debris that makes it out, rather like an airline or a water jet the pressure (and thus risk of unjury) drops off almost exponentially as there is nothing of mass.
You can't "Easily add the effects in post processing" because it's actually hard to mimic the recoil of a gun as it has to happen at exactly the right point, and to do so you'd need to basically redraw the entire arm and gun as well as add in the flash and bang.
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