By Dalton Ross
July 18, 2014 at 01:00 PM EDT

While on break from The Walking Dead this past spring, Norman Reedus did a little moonlighting on a new movie being produced by his TWD buddy Robert Kirkman. That movie is called AIR, costars Djimon Hounsou, and will be released in the spring of 2015. But while telling Entertainment Weekly about the project, Reedus revealed that he got a bit more than he bargained for during filming. “I’m excited about the movie,” says Reedus. “The director, Christian Cantamessa, is going to be a huge director. And it was such a cool script and such a cool working environment. And Djimon is just awesome in the film. I’m excited for people to see it. It’s completely different from The Walking Dead, and we worked truly hard on that film. Actually, I broke my toe.”

Wait…WHAT?!? Broke your toe? How exactly did that happen?

Kicking. Kicking Djimon.”

Okay. Explanation now, please.

“I went off on him in a scene and I just started kicking him,” explains Reedus. “I had him hold the bottom of his foot, so I could start kicking his foot. But he’s so rock hard and made of muscle that I broke my toe when I was doing it. It was an unmanly move, and I’m screaming at him. I’m like ‘Ow! Ow! Ow! Ow! Ow! Ow! Ow! Ow!’ They had to take me to the emergency room in the middle of the night. It was a strange experience.”

As for the man producing the film, Robert Kirkman says Reedus’ injury is a case of no pain, no gain. “He sort of hurt his toe in the process,” admits Kirkman. “I feel a little bad about it. But I think the movie’s going to be great, so it’ll be worth it in the end.”

For more ‘AIR’ intel, check out Entertainment Weekly’s Comic-Con preview package, on stands now. Also, follow Dalton on Twitter: Follow @DaltonRoss