Building the Set
As a department, we started by looking at the model box and technical drawings. We discussed what needed to be made and what could be bought in. We also got put into three sub groups so that we could all focus on small sections instead of the whole thing. I was put in a group with Chelsea, and we were assigned the forest sections. We looked at the forest and decided what each part of it should be made of. We also discussed what order would be the best to complete the parts. By knowing the scale, which was 1:25, and measuring the items in the section, we could work out how much of each material we needed.
Staging:
The first thing we started to put together was the staging. For this, we looked at the plan and worked out how many legs we would need. We decided that we wouldn’t have a leg in every single hole, to avoid having two legs in the same place on two different decks. For instance, when we joined two 8” x 4” decks together, we would have one deck with four legs, and the other deck with two legs. As we joined them together, we wouldn’t need twice the number of legs where they are connected. We decided to count the number of legs needed first, before starting to assemble the staging, so that we could prepare all the lengths we needed to speed up the installation of the staging.
After working out the length we needed, we went searching for as many as we could find that were either the same length, or slightly longer, so that we would waste the least amount possible. After searching around we realised that we would have to cut a lot, but that wasn’t a problem. We measured the length with needed with a tape measure and put a pen mark where we needed to cut. We then used the metal grinder to cut the pole to the right size. After doing this to the poles, we used the angle grinder to smooth off any shaper edges so that it was safe to be handled and used.
When setting up the staging, we would put the legs into the hole they went and tighten up the bolts. This was to ensure that the legs would not fall out when put upright and it made it more rigid. We would then put it upright and if it was against another staging piece, we would put at least two bolts between them, connecting them together.
Handrails:
The handrails were a tricky and interesting challenge to overcome. We wanted something non-intrusive but also strong enough to stop people from going past them. We decided to use metal wire, as it can be nearly invisible in the right light, but very strong. We could also put it under high tension to make it a lot harder to push past it.
We didn’t have any supports to put the wire between so we designed an upright that could be used and made it. Firstly, we got a 2” (two inches) by 1” (one inch) metal bar as the main upright. We cut it to the right length of 3’ (three foot), which is long enough to stop someone, but not long enough to get in the way of sightlines. We then found a long piece of flat bar that had been folded in half lengthways to create a corner. We used this, after it had been cut down, to create a lip at the bottom of the bar.
When cutting the bars, I ensured I had goggles on to protect my eyes from the tiny shards of hot metal, and ear defenders to protect my ears from the excess amount of noise.
We welded this onto the bar so that it would be attached strongly and won’t come off with a bit of pressure. After attaching this piece of metal, we lined it up with a piece of decking and marked where the hole needed to be. After double-checking that the hole is in the middle of the bar, I took it to the pillar drill and slowly drilled a hole through the metal. This hole is so that we can put a bolt in and attach it to the decking. I then put a plastic cap on the top end so that if an actor put their hand on it, it would be safe and not hurt them. After putting the cap in, I then drilled a hole an inch from the top to put the wire through.
Tree Trunks:
After discussing with my team, we decided that the tree trunks would be made out of carpet tubes. These are long cylinders that are made out of cardboard. They are normally used to transport large pieces of canvas or to put carpet around them to be stored. We decided to use these as they were already the right shape for what we needed. After a lot of research, we found a few websites that sell similar to what we wanted, but none that sold them long enough. We then looked at some tubes we already had in the workshop, and found out where they were from. We phoned up the company and ordered some to be delivered.
After they arrived we cut a third of them in half. We did this by measuring the length, dividing by two and then putting marks all the way around at that distance. We then used a handsaw to cut the tubes in half.
We then cut some pieces of wood to small lengths so that we could glue and staple them in the top of the tube. This meant that we could then slide another tube on top and attach them together. We did this so that we could have longer trunks, so that they would reach the top of the theatre.
When we were installing the trunks into the staging we first planned out exactly where we wanted them to go. We placed the white caps on the floor in the right places so we could make sure there was enough space between them. To keep them in place, we screwed the white caps onto the decking, and put the trunks onto them. We then stapled them to the caps. We realised that this would not be enough to keep them staying upright, so we cut a piece of wood roughly the right size and then used the bad saw to make it curved.
We attached this piece of wood to the end of the tubes. We then drilled a hole in it and used a twisted boom arm to attach it to a lighting bar.
Branches:
We decided to use polystyrene to create the branches for the trees. This was so that they were light enough to be attached to the trunks, whilst also be hung from the lighting bars.
We used the branches from the model box and an overhead projector to project a shape onto a large sheet of polystyrene. This meant that we could use the designs from the model box to create the large-scale versions. We used a chalk on the end of a stick so that we wouldn’t get in the way of the projection.
We then used a hot element to cut out the branches.
Ladders:
For the ladders on the side of the staging, we decided to use some ladders we already had, so that we knew they would be strong enough. I had to check the ladders and make sure that there was nothing that is sharp or sticking out, so the actors couldn’t hurt themselves. I then welded on a plate so we could screw it to the decking.