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How to Build a Theatrical Flat

Much of art works because it creates a successful illusion. In the art of theater, illusions help set the scene and establish vivid realities with nothing more than wood, cloth and creative lighting. Artificial background elements or "flats" help establish the illusion of a defined space from a wallpapered living room to a forest glen. Regardless of the illusion you wish to establish, you can build a sturdy, effective theatrical flat with some basic stage carpentry techniques.

Things You'll Need

  • Safety glasses
  • 1-by-3-inch pine boards
  • Circular saw
  • Wood screws
  • Power drill
  • Driver bit
  • 1/4-inch plywood
  • Pneumatic stapler
  • 5.2mm lauan plywood boards
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Instructions

    • 1

      Put on safety glasses.

    • 2

      Cut two 4-foot lengths from 1-by-3-inch pine board with a circular saw. These will provide the top and bottom or "rails" of the flat frame.

    • 3

      Cut two 8-foot, 11-inch lengths from 1-by-3-inch pine board with a circular saw. These will provide the left and right supports or "stiles" of the flat frame.

    • 4

      Place the rails and stiles on a flat work surface so that they form a 4-foot-by-9-foot-6-inch rectangle.

    • 5

      Drive two wood screws through the top rail into the long end of one of the stiles with a power drill and driver bit. Repeat this process with the remaining three ends of the stiles.

    • 6

      Cut two 3-foot, 5-inch lengths of 1-by-3-inch pine with a circular saw. These will profile central supports or "toggles" for the flat frame.

    • 7

      Place one toggle so both ends touch the inner side of both stiles at approximately 4 feet from the top of the frame, and place the second approximately 1 foot, 6 inches from the bottom of the frame.

    • 8

      Drive two screws through the right stile and into the long end of the top toggle with a power drill and driver bit. Repeat this process with the remaining three ends of the toggles.

    • 9

      Cut four 8-inch square triangles from 1/4-inch plywood with a circular saw. These will provide "corners" for the flat to help hold the frame together.

    • 10

      Place each corner over the corners of the flat where the stiles and rails meet.

    • 11

      Staple each plywood corner in place with a pneumatic stapler.

    • 12

      Cut four 3-inch-by-8-inch rectangles of 1/4-inch plywood with a circular saw. These rectangles or "keystones" will help strengthen the toggle and stile joints of the frame.

    • 13

      Place each of the keystones over the middle of the toggle and stile joints parallel with the toggles.

    • 14

      Staple the keystones in place with four staples using a pneumatic stapler.

    • 15

      Cut a piece of 5.2mm lauan board measuring 1 foot, 6 inches with a circular saw.

    • 16

      Place a full-size 8-foot piece of 5.2mm lauan plywood over the opposite side of the frame from the corners and keystones. Place the 1-foot, 6-inch piece of 5.2mm lauan over the bottom of the frame so the plywood covers the entire surface evenly.

    • 17

      Drive wood screws through the lauan and into the rails, stiles and toggles approximately 6 inches apart using a power drill and driver bit.

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