CNC Cast Iron Park Bench

Yes, I built this exact same cast iron park bench seven years ago. I even used the same research image you see in the link. I couldn’t build it the same way, though. The first time around, I used a lot of found pieces and details which I did not possess this time. I also needed to build three matching benches, which warranted a different approach then building a single one. I was building and buying all the props for Elon University’s production of Cloud 9, and the whole second act takes place in an English park; the director was keen on basing it off of Kensington Park. We decided to cut and carve the ends on the scene shop’s CNC router.

Rehearsal bench
Rehearsal bench

First I built the seats themselves with some stand-in legs and arms. I arranged some slats I had cut into a shape that was comfortable to sit in, than I screwed them together onto supports which kept the whole thing sturdy. The stand-in legs held it all up at the correct height so they could rehearse with the benches while we worked on the real ends. The idea was that when the real ends were ready, we would just unscrew the fake legs and pop on the real ones without having to take apart and reattach all the original slats. This also ensured that the curve and depth of the seat they were using in rehearsal would be exactly the same on the performance benches.

I began by making a line drawing of the bench in Inkscape, an open source vector graphics editor. I drew three layers; the first was a line showing where all the inside “holes” should be cut and the second showing where the outermost profile should be cut. The third layer showed where all the engraving would go. Rather than cutting all the way through the plywood, the router would only cut partway down, and it would use a v-shaped cutting bit (this technique is known as “v-carving”).

Primed bench end
Primed bench end

With the drawings finished, I gave them to the Natalie Hart, the scene designer (also my wife), to import into AutoCAD. I’m sure you can use the Inkscape drawings directly, but I have no experience with CNC file formats, and Natalie has already successfully used her CAD drawings on the CNC machine. The curves I drew in Inkscape turned into a series of many tiny lines in AutoCAD; this meant when they printed, they looked like many tiny lines rather than a single smooth curve. The curves she redrew in AutoCAD printed as smooth curves, however. I’m not sure I will use Inkscape again to draw for a CNC; if I find myself using the CNC a lot in the future, I may just spring for one of the less-expensive CAD drawing programs out there.

Closeup of CNC V-carving
Closeup of CNC V-carving

The final piece of the puzzle was getting the drawings into PartWorks, which is the CNC machine’s software that generates the instructions it uses in cutting. Our production manager/lighting designer Bill Webb happily took that on, since the machine is second-nature to him by now. In about three hours, we had all the pieces we needed for all three benches.

You can see in the photograph above that the CNC left a lot of cleanup work to do. I experimented with a number of abrasive flap and wire wheels to see if there was a quick way to sand the whole thing, but it ended up requiring hitting every nook and cranny with a Dremel tool.

Inside of bench end
Inside of bench end

We had taken measurements off the rehearsal benches and put them into AutoCAD so the CNC parts would line up exactly with the existing structure. For the inside of the end, we only printed the bottom half and attached it to the outside part. This gave a bit of a lip for the existing bench seat to rest on, while also providing a lot of surface area to screw into from the side. It also helped line up the bench seat to the ends at the correct height.

The faux-verdigris paint treatment was developed by one of the students (good job, Vee Bland!). Natalie and I painted them up, and I quickly assembled them so they would be ready mere minutes before photo call.

Finished bench
Finished bench

Naturally, I would have loved to play around with the software and the drawing to develop a more realistic carving, as well as spend some time learning to run the CNC machine on my own. The time frame on this production was just too intense; 15 days between the first day of rehearsal and opening night, and these benches were but a small part of all the props and furniture I had to build and acquire. Still, it gave me a good idea of how I can integrate CNC fabrication into my prop work when it can come in handy.

Friday Prop Notes

I just finished tech on my first show this year (with opening night tonight), so the links are a bit sparse this week. But all of them are great, so enjoy!

There is a fun article up this week about Jim Bussolati, prop master at Louisiana State University. It also has a wonderful video showing off their storage and shop.

Matt Munson has a great blog post up called Materials, Time and Creativity. He talks about why custom-made props cost so much money. It’s a worthwhile read, whether you are a freelancer or work in a shop.

2StoryProps has quite the extensive post up about building a “Deadmau5 Cheese Head” (a helmet used by a Canadian DJ). There are photographs and videos galore, so it will take some time to get through this one, but it is well worth it.

It is sad, but not too surprising: New York City Opera is liquidating their warehouses. Their collection of props, costumes, lighting and other equipment from over eighty productions are being sold through an online auction until January 30th (though the website isn’t quite ready yet).

Making a Plaster Mold

I have a new video up on the videos page of The Prop Building Guidebook website. This one deals with making a one-piece plaster box mold. Plaster is a cheap and relatively easy-to-work-with molding and casting material, and a one-piece box mold is one of the most basic types of molds to make. I feel a one-piece plaster box mold is one of the best introductions to mold making for those reasons. If you can pull it off, you’ll have more success as you move on to silicone rubber and other fancy mold-making materials.

So check out the video below, and don’t forget that I’ll have new videos up every week until my book comes out on February 26th.

William Bradley, Property Man, 1927

This article first appeared in the February 20, 1927, issue of The New York Times.

With the trend of the drama toward realism it is obvious that the relative importance of the property man in the theatre must have increased considerably. In the barn-storming days of the early ’90s a revolver, a window-sash and a back-drop depicting Niagara Falls at its most gushing moment, comprised an almost complete set of props. Today, the man whose business it is to supply all the effects necessary to create an authentic background must produce as part of his day’s work everything from a flying carpet to a cat’s meow.

It is just such effects that William Bradley, who has been tracking the prop to its lair for lo, these many years, has on tap at his studios. Bradley’s first experience in playing valet to the stage began in 1885 when he worked at the old Standard Theatre. In 1892 he wandered out to Dayton, Ohio, with his trusty three-piece set of props. There he not only dressed the stage, but he also did a song and dance turn, tended door on the balcony, and also rehearsed the orchestra for the incidental music.

In 1908 Bradley returned to New York to begin work as property man with the late Henry B. Harris. It was while furnishing the Harris productions with properties that he conceived the idea of opening a studio upon which producers could call for data and incidentals. On Mr. Harris’s death Bradley started in the property supplying business. Today, no matter what article of stage adornment is necessary to a show he will usually find it.

Any number of interesting quests fall to his lot. Take, for instance, the little matter of shark teeth. It isn’t often that the voracious specimen of cartilaginous fish, or even any portion of his anatomy, is called upon to make a public appearance. Naturally, Bradley thought that the shark would be pleased—nay, even willing—to turn professional. But not a bit of it. The property man spent a lively few days trying to gather together enough shark teeth to make a necklace. He searched high and low and at last rounded up two stuffed shark heads with the idea of extracting the necessary ivories. But the heads refused to lose their teeth. So the hunt for the necklace continued.

It was a week later that Bradley journeyed to the Syrian quarter on Washington Street looking for some pipes for another production. He happened into a Turkish delicatessen store. It was bargain day for dried okra, and Mr. Bradley was the recipient of an idea. Buying the okra, which is usually used for soups, he took the bag of herbs to his studio, hung the pieces on a string, and thus was born a necklace of shark teeth that, so it is said, would have turned any South Sea Islander green with envy.

It was in Dayton that Bradley first met George C. Tyler, whose productions he now outfits. Mr. Tyler was, at that time, a press agent with an eye on the producing end of the business. But the two did not meet again until Mr. Tyler did Tarkington’s “Clarence.” Ever since then Bradley has found the props for all Tyler shows, whether they be modern comedy or historical drama.

It is necessary for the property man, if he is to make a real business of his work, to have at his disposal a fund of information concerning almost every historical period in almost every country. In “The Constant Nymph” for example, Bradley was called upon to supply the props for a Tyrolean home. This meant that he had to furnish the potato barrels, the clumsy stools and tables, the pottery from which the characters eat, and that they all had to be true to life. For the property man never knows when some experienced traveler or historian, or even a native of Tyrol, may be sitting out front waiting to catch him up. And natives of Tyrol, it seems, are given to doing this.

Periodicals from a specific locality are often difficult to procure. There is in “Tommy” a call for a telephone book from a small town in New Jersey. This was fairly easy, for it meant that the property man made overtures to the town and procured the required prop. The question of having newspapers of a definite date and place on the stage is another problem—not a difficult problem, to be sure, but one that demands the attention of the property man. Should the “prop plot” call for the current issue of a daily paper, it is that functionary’s job to see that each day a fresh paper is supplied. Only he knows how many people out front will catch a slip-up on his part—and how many have!

The greatest demands on the property man today are for modern appliances, such bathtubs and kitchen furnishings as are used, say, in “Saturday’s Children.” These are easy enough to furnish and a supply is always at hand.

Originally published in The New York Times, February 20, 1927.

Summer Jobs Already?

For those of you in school for theatre, it is not too early to start thinking about summer employment. Even though snow is still on the ground and it gets dark at 4 pm, this is the time of year that many summer festivals, theatres and operas begin recruiting for their production positions and internships. To my international readers, I am sorry this post only deals with US jobs and internships.

Whether looking for summer work or for immediate work, Backstage Jobs should be one of the sites you check daily. By now, most of the major and legitimate theatres have learned to post any and all technical and production-related jobs to this site. It is completely free to view every job posting. The site admin also does a bang-up job of keeping spam and unrelated postings from appearing.

Speaking of spam, the Society of Properties Artisan Managers maintains a list of which of their member theatres offer props internships. This is a comprehensive list of all internships, not just summer ones, so be sure to check the commitment dates for the theatres you are interested in.

Artsearch is another big mainstay of technical theatre job postings. Though you should avoid job posting sites which require you to pay to view listings, this is the one exception. If you are currently in school, your school will probably have login information you can use (this is often true if you are an alumni as well).

In addition to job listings online, you may wish to think about applying and interviewing for jobs during one of the two big conferences. Though these are held in March, now is the time that you should be registering for the conferences, booking your hotel and making your travel arrangements. The two major conferences for theatre technicians are USITT and SETC.

This year, USITT is held March 20-23 in Milwaukee. The conference is meant for technicians and designers for all aspects of live performance. Part of the conference includes a massive stage expo, where companies and employers have booths to show off what they do. This is where you can meet and greet with the people in charge of these companies; many of them use USITT to do some of their recruiting for summer internships and apprenticeships.

The SETC conference will be held March 6-10 in Louisville, KY. SETC is meant for all aspects of theatre, including acting and directing, so it is not focused on just the production side. While the exposition hall is much smaller than USITT’s, it does have a job fair you can sign up for. Companies have small tables where they list the job openings they have, and you sign up for times to interview. You then spend the rest of your time meeting with employers all over the convention center to interview for these jobs. You can interview for as many or as few jobs as you have time for. I actually got hired at the Santa Fe Opera for the first time at the SETC job fair.

These websites and conferences have jobs at all skill and pay levels; even the internships can vary widely in how much you are paid. While it may seem your acting friends are constantly taking low-to-no paid internships, as a technical theatre person, you should always be paid for your work. Plenty of paid opportunities exist at all skill levels if you look for them.

Making and finding props for theatre, film, and hobbies