All posts by Eric Hart

Useful Sites

Weekend Prop Stories

Inside the ‘Jitney’ Set: Picturing Pittsburgh Onstage – The NY Times takes a look at how set designer David Gallo and props supervisor Scott Laule brought the set to August Wilson’s Jitney to life. Set in 1970’s Pittsburgh, a lot of the set dressing and details come from conversations with Wilson himself when Gallo designed the original set back in 2000.

The tiny town that builds show-stopping sets for Beyoncé, Kanye and Madonna – This is such a great article on all the massive scenic shops which exist in Lititz, PA, the heart of Amish country. I grew up not too far from there, but I never knew that companies like Tait Towers have built nearly every rock and roll set here since the late 1960s. The larger tech theater schools send a lot of their graduates there, but most people are unaware how much fabrication and painting work can be found in the area.

This ‘Circus’ has elephants … in puppet form – A circus is not much of a circus without elephants, but most of these elephants are poorly treated. So the only humane solution is to build life-size puppet elephants. USA Today gives us a close-up look at how the puppet elephants in Circus 1903 come to life.

Batman’s Original Utility Belt Was Made Out Of Sponges – The headline tells the story. Before HD, television shows could get away with glueing brightly colored sponges to a belt and calling it a Batman costume. I have also heard that some of the phasers in the first season of Star Trek: The Next Generation were simply painted blocks of balsa wood.

Giant, Flame Spewing Animatronic Dragon – The only thing better than a life-sized elephant puppet is a giant, flame-spewing animatronic dragon. Check out how Zollner Electronics fabricated this monster for a seasonal folk play in Germany.

How-to

Sofa from The Price

We recently closed Arthur Miller’s The Price at Triad Stage (preceding the Broadway version by a few weeks). With a week before tech, a concern arose that the “Biedermeier-style” sofa blocked too many sightlines. We needed a backless version, and since nothing like that exists in our stock, I had to build one.

Tracing the profile
Tracing the profile

The designer, Fred Kinney, found a research image he liked. The photograph was taken straight on from the front, so I was able to trace it directly onto some plywood with an overhead projector.

Cut outs
Cut outs

I made each front and back piece out of three pieces of plywood and doweled them together. I have some temporary blocks attached in the photograph above to help clamp them. They will also be held together in the back by the cushion frame.

Building the base
Building the base

The base for the cushion was just a simple platform frame.

Cushion
Cushion

The cushion for the couch was a separate piece made of high density foam on top of a sheet of oriented strand board (OSB). The whole thing can be removed from the couch at any time. The plywood from the home improvement stores is so prone to warping; I’ve switched to OSB for my upholstered pieces because it is one of the flattest sheet goods you can buy there. It is really cheap too, though it does add a bit of weight and you have to build a good frame underneath it.

Armrest
Armrest

The armrests needed to be long pieces of solid wood shaped into a rolling curve. I traced the curve onto several smaller pieces of lumber, and cut away most of the waste with several passes through the table saw. After gluing the pieces together, I smoothed all the angles into curves using a belt sander.

Unpainted piece
Unpainted piece

I routed the edges of the front and back to give them a decorative profile. The armrests were screwed in, but I also ran a large through-dowel to help support them since actors were going to be resting there. I also doubled up the plywood on the legs and arms to make them appear thicker and to give more structure.

Backless couch from The Price
Backless couch from The Price

The inside panels of the arms were covered in fabric, while the outside panels were capped with a piece of wiggle wood. The whole thing was painted and covered in amber shellac. I found two rosettes in stock and added them to the center for that final decorative touch.

Features

From Prop Making to Authoring

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Last Thursday, I gave a talk to the Alamance Makers Guild at STEAM Junction in Burlington, NC. I’ve been a member of the AMG since 2012, and it was great to finally give a featured presentation. STEAM Junction is the new Maker Space started by the same people.

My talk was called “From Prop Making to Authoring.” I started off discussing my career as a prop builder and what that entails, before moving onto the blog and how that ultimately led to writing The Prop Building Guidebook: For Theater, Film, and TV.

My wife broadcast the entire talk over Facebook Live, and now the video is up on YouTube. It is a little over an hour long, so only the most diehard fans will make it through the whole thing.

The audience really enjoyed it. I was able to explain how my work informed the blog and how that built an audience for the book. I talked about why I blog, and how I use social media to promote it. Much of what I discussed was relevant to makers of all kinds, not just those who build props. It is all about teaching and sharing knowledge, and how to get people interested in what you do.

Useful Sites

Mid-February Prop Links

Shop Tips: Cutting Foam for Propmaking – First up, Tested visits Frank Ippolito’s shop to see what tools he uses to cut flexible foam sheets. I want to try one of the blades he uses, which allows him to make some interesting cuts.

Shinken Sword Commission – The Prop Solve is back with an epic post on fabricating a fantasy sword for a client. The post is filled with pictures of every step, showing not just the successes, but the mistakes and learning experiences along the way. I especially like the build break-down she prepared for her client.

Queens Prop Shop Has Crafted Real Name for Itself in Booming Industry – NY1 visits the Prop “N” Spoon warehouse over in Queens and fabrication shop in Rahway, NJ. Check out the video to see some of the cool props they have built as business booms in NYC.

Adam Savage Examines the Props and Spacesuits of The Expanse! – We go back to Tested for this video of Adam Savage talking with James Murray, props master for Syfy’s The Expanse. Check out all the scratch-built armor, weapons, and other sci-fi elements for this sprawling space adventure.

Paperhand puppet master takes Chapel Hill-Carrboro teachers to school – In local news, puppet maker Donovan Zimmerman is teaching puppetry to local elementary students. Zimmerman is cofounder of Paperhand Puppet Intervention, which produces incredibly imaginative and poetic masks and puppets out of mere cardboard and papier-mache. It’s a wonderful program that will probably be cut as both art and education are eliminated in the next four years.

How-to

Fiberglass with Aqua Resin

When we think of fiberglass, we think of the smelly, toxic resins used to reinforce it. Many props people avoid fiberglass for that reason. Water-based resins offer a less toxic alternative. Aqua Resin is one brand which is useful for theatrical prop building with fiberglass. You need a dust mask when handling the powder, but once mixed, it is non-toxic.

In my latest video, I show how to make a prop using fiberglass with Aqua Resin in a one-piece negative mold.

You can see how the mold was made in my post on matrix molding, and you can see photos of the finished prop in my post on the Magic Seashell.

Using fiberglass is one of the techniques that now has a step-by-step photo tutorial in the second edition of The Prop Building Guidebook: For Film, Theater, and TV, which comes out February 10, 2017. You can see all the companion videos at the Prop Building Guidebook website.