Set Construction
What we ll be learning today The use, construction of, and terminology of typical scenic elements The lumber, tools, and hardware used to build these scenic elements
Stock Scenery Stock scenery is standardized rectangular flats (including door, window and fireplace flats) which can be easily assembled into a set. Because they are standardized, they can be quickly repainted and used in another production. The use of stock scenery can reduce the set budget for a show to the cost of paint.
CCA Stock Scenery CCA uses flats and platforms as our stock scenery. Flats are used as walls. Platforms are used as floors (must be weight-bearing) to create different levels (alone or with legs) or wagons which are platforms on casters (wheels). The traditional theatrical flat has a wooden frame with muslin (a canvas-like fabric) facing. All of our flats are hard flats. They have lumber facing.
A CCA Set Made with Stock Scenery For a show with a VERY low budget
Hard Flats There are 2 ways to make flats Theatrical Flats Framing lumber is laid flat Requires use of corner and joint bracing, especially when using muslin (fabric) facing Hollywood or TV Flats Framing lumber is on edge The hard facing helps keep the flat sturdy without the use of joint bracing All of our stock flats are Hollywood flats
Theatrical Flat
Flat Terminology Rail: the top and bottom, horizontal pieces of the frame Stile: the side, vertical pieces of the frame Toggle: the internal, horizontal pieces of the frame
Hollywood Flat
Discussion Theatrical vs. Hollywood Flats What are the benefits or different uses of each version?
Platforms Framing for a Hollywood Flat and Platforms are the same, however the lumber used is different
Lumber for Flats Frame 1 x3 stock lumber (usually pine) Actual size is approximately ¾ x2 5/8 or 2 ¾ Typically comes in 8-16 lengths Facing 1/4 width lauan (mahogany underlayment) Typically comes in 4 x8 sheets Actual size may vary
Lumber for Platforms Frame 2 x4 stock lumber Actual size is approximately 1 ½ x3 ½ Typically comes in 8-16 lengths Facing ¾ Stock Plywood Sometimes comes as 23/32 which is slightly less than ¾ Typically comes in 4 x8 sheets
Discussion Flats Vs. Platforms Why do we use different lumber for flats and platforms even though the construction is the same?
Tools for Construction Compound miter saw, aka Chop saw Used to cut long, skinny lumber Used to cut 1 x3 and 2 x4 lumber for flats and platform frames
Pneumatic staple gun and air compressor Staple guns come in different sizes and can use different size staples We use staples to put together flats 1 ½ or 2 for the frames, 1 for the lauan facing Tools for Flats
Tools for Platforms Cordless driver Using the Phillips head screw tip Use for platform frame and facing Use 2 ½ or 3 coarse thread drywall screws for frame and 1 5/8 screws to attach plywood facing
Discussion Screws Vs. Staples Why do you think we sometimes use screws and sometimes use staples in theatrical construction?
More tools and materials Wood glue to use on flat joints Tape measures for lengths of lumber cuts Measure twice, cut once!!! Pencils Triangle Square or Right Angle to make sure you have 90 degree angles in each corner
Router Trim overhanging edges (straight bit) or round the edges (curved bit) Finishing Tools Different router bits
Finishing Tools, cont. Sander for a smooth finish Belt (right) Palm (below)
Size of Flats and Platforms The standard stock flat and platform is 4 x8. (For a flat 8 is the height.) Various combinations of even-numbered lengths are also common e.g. 2x8, 4x4. Toggle bars (the interior braces) are placed every 2 apart.
Measurements for Cuts of Lumber for the Frames Because the rails (top and bottom edges) are on either side of the stiles (side edges), you will need less than 8 for the stiles. You need to subtract 2x (1x for the top rail, 1x for the bottom rail) the thickness of the lumber used for the rail from 8 to get the actual length of the cut of lumber used for the stile. The same goes for the toggle bars which are set inside the stiles. Subtract 2x the thickness of the lumber used for the stile from 4 to get the actual length of the cut of lumber used for the toggle.
Do the Math What size cut would the stiles be for a platform? Use 2 x4 lumber for platform frames Actual size of 2 x4 is approx. 1 ½ x 3 ½ Platform frames built with lumber on edge= 1 ½ thickness 1 ½ +1 ½ =3 Length of platform =8 =96 96-3 =93 or 7 9
Create a Cut List Cut list for a 4 x8 flat 1 x3 lumber 2 @ 48 2 @ 94-1/2 3 @ 46-1/2 The lauan facing will be a full sheet and will not need to be cut
Key Terms Stock scenery Theatrical Flat Hollywood Flat Rail Stile Toggle (bar) Platform Wagon Caster Pneumatic Triangle Square Muslin
Practice In pairs, you are going to create a construction drawing and cut list of a 2x2 cubby shelf. The opening of the cubbies should be 1 tall x1 wide x1 deep. Create an orthographic projection or an isometric, oblique, or cabinet drawing. The lumber will be ¾ thick plywood, except for the backing, which will be ¼ thick lauan.