Stage flats are essential for creating scenery and defining spaces in theatrical productions. Here's a guide on how to make them:
Materials:
* Wood:
* Framing: 1x4 or 2x4 lumber for the frame
* Sheathing: 1/4" or 1/2" plywood, luan, or Masonite for the surface
* Tools:
* Miter saw or circular saw
* Drill
* Tape measure
* Level
* Hammer
* Screwdriver or drill/driver
* Safety glasses
* Hardware:
* Wood screws or nails
* Corner brackets (optional)
* Optional:
* Primer and paint for finishing
Instructions:
1. Determine Flat Size:
* Consider the dimensions of the stage and the scenery you want to create.
* Flats are typically made in standard widths like 4', 8', or 12'.
* Height can vary based on your needs, but 8' or 10' is common.
2. Cut Framing Pieces:
* Cut two long pieces of lumber for the top and bottom rails of the flat.
* Cut two short pieces for the side stiles.
* Make sure the side stiles are the same length as the desired height of the flat.
* Cut the top and bottom rails to the desired width of the flat, minus the thickness of the two side stiles.
3. Assemble the Frame:
* Lay the bottom rail flat on a work surface.
* Position the two side stiles on each end of the rail, ensuring they are perpendicular to the rail and flush with the edges.
* Attach the side stiles to the bottom rail using screws or nails.
* Repeat the process for the top rail, ensuring it is parallel to the bottom rail.
4. Add Intermediate Rails (Optional):
* For larger flats or to add extra support, you can add intermediate rails.
* Cut these to the same width as the top and bottom rails and attach them to the side stiles at equal intervals.
5. Attach Sheathing:
* Measure and cut the sheathing to fit the inside dimensions of the frame.
* Attach the sheathing to the frame using screws or nails, ensuring the sheathing is flush with the edges of the frame.
* Apply a bead of wood glue along the edges of the sheathing for extra strength.
6. Reinforce Corners (Optional):
* Use corner brackets or additional wood to reinforce the corners of the flat for added stability.
7. Finish (Optional):
* Prime and paint the flat according to your design needs.
Tips:
* Use a level to ensure the flat is square and the rails are parallel.
* Pre-drill holes for screws to prevent splitting the wood.
* Use a combination of screws and wood glue for a stronger joint.
* Consider using a router to create a lip on the front edge of the flat, which will help it align with other flats.
Variations:
* Double Flats: These consist of two flats hinged together to create a thicker, more sturdy structure.
* Scrim Flats: These use lightweight fabric stretched over the frame to create a translucent surface.
* Platform Flats: These are strengthened with additional bracing and plywood on the bottom to create a stable platform.
Safety:
* Always wear safety glasses when using power tools.
* Use caution when handling sharp objects.
* Lift heavy flats carefully to avoid injury.
By following these steps, you can create durable and functional stage flats to help bring your theatrical productions to life.