Tag Archives: materials

Making a Cast Iron Park Bench

First, I wanted to mention that I have redone and updated my online portfolio; it was in desperate need of an overhaul, especially now that I am freelancing again. I went with a free site at CarbonMade.com, because the thought of designing and coding yet another portfolio site was making me tired just thinking about it. I’ve seen some other prop makers who use that site to show their work, and so far, it seems to be working well. Let me know what you think!

Now then, let’s take a look at a bench I made back in 2006 at the Santa Fe Opera. I basically had to build the whole thing from scratch in less than a week, so it’s a bit rough.

Research image
Research image

They wanted a cast iron park bench. The only real requirements were the size, so I had to find my own research image. I showed the above photograph to Randy Lutz, the prop master, and he agreed it was a good bench to duplicate.

Basic layout of sides
Basic layout of sides

I drew a full-scale layout of the side on a piece of paper and spray-glued it to a sheet of plywood. You’ll notice the decorative parts do not match the photograph exactly. What I decided to do was pull some decorative resin castings and carved wood pieces from stock—the opera has quite a good collection of these. I then arranged them to match the research as closely as possible. I traced them and cut away the extra plywood. You’ll see in a bit when I start gluing them on, it’ll all make sense.

Adding the back and seat
Adding the back and seat

I cut out and added some support runners on the insides of the two ends and began to attach the slats which would make up the back and the seat. It needed some extra support, so I ran a rod along the bottom; you can see it in the next photograph.

Adding applied details
Adding applied details

Now I began attaching the decorative resin bits. I also used some Ethafoam rod cut in half to make some curved half-round molding. I found a strip of upholstery fringe which added more texture.

Closeup of details
Closeup of details

Here’s a closeup showing some of the resin bits and Ethafoam, as well as some rosettes and even bits of yarn. If you look really close, you can even make out a bit of hot glue design work; though it’s practically invisible here, once the paint goes on, it will add just that extra little bit of texture that will make the whole thing seem like a single piece of cast iron from the audience.

Paint job
Paint job

The paint job is what really helped marry all the different materials together and bring the whole thing to life. The painter of this bench worked as one of the other props carpenters for the beginning of the summer, so none of us knew how good he was at scenic art until he did this bench.

Completed bench
Completed bench

So here it is, ready to go on stage. I even added some round bolt heads running down the middle so it looked like the slats were bolted to the legs. Overall, it was a fun piece for the short time frame I had to build it in.

Salon on Being Green

Yesterday at Wingspace Theatrical Design I attended their salon on “Being Green.” The featured guests included set designer Donyale Werle (Bloody Bloody Andrew Jackson, Broke-ology), as well as Annie Jacobs and Jenny Stanjeski from Showman Fabricators.

A lot of the facts which were presented are better summed up in my post on a previous workshop I attended called “Going Green in Theatrical Design.” I did see something that was new though (new to me, that is): UC Berkeley’s Material and Chemical Handbook which presents some of the materials we commonly use in prop making, along with disposal instructions and safety notices. It’s specific to their college, but it is a good starting point for developing your own.

Since I didn’t take notes, what follows is more of a highlight of various points made in the discussion as I remember them:

“Being green is not black or white”; it is not an either/or proposition. Rather, every day you try to make better choices, and every show you try to do a little greener. It takes a lot of experimentation, a lot of analysis, and a lot of effort.

Do not do bad “green” design and art; it’s worse than no design. The goal is to make good design, and the goal of sustainable theatre is to do it a little greener each time.

As theatre people, we already come from a culture of sustainability and recycling. We reuse and repaint flats and drops. We take the lumber from one show and use it on the next. We borrow and barter the costumes and props from other people doing the same. But as our careers progress and the shows get bigger, we get away from that. Maybe it’s because you get to work with bigger budgets, or maybe it’s because you want to push your work to have higher production standards. Making sustainable theatre is a conscious choice and takes a concerted effort.

One of the problems, someone pointed out, was in trying to do a green production with a designer who was still in the old mindset—the mindset that everything has to be new and bought just for that show. What is the new mindset? It may mean a design which evolves from the available materials, rather than a design which starts on paper and then requires the purchasing of all new materials. Maybe it just means less design, though as Donyale pointed out, she likes a lot of “stuff” in her designs:

Bloody Bloody Andrew Jackson
Bloody Bloody Andrew Jackson

Thinking about more sustainable options means taking more time out of your already busy schedule, and asking others to take more time as well. Donyale pointed out that if you can do case studies on what you’re spending versus what you would spend in a more traditional production, you can convince the producers; for Peter and the Starcatcher, she calculated that they saved $40000 in materials by using recycled, salvaged and upcycled materials, but that the labor cost was a third more due to all the sourcing and processing of this material. Still, it was an overall savings; the extra labor cost was offset by the reduced materials cost. Producers like to see savings. It is also, for a lot of us, morally preferable to have more of the money to go to human labor (which is sustainable) than to the purchase of materials shipped from across the globe which will end up in the trash once the show is finished.

For artisans and production people, as opposed to designers, using more sustainable techniques means taking time to do your own experimentation and comparison of materials and techniques to arrive at better solutions. If you can come up with concrete alternatives to show your designers, it becomes easier to convince them to trust you. An example the ladies from Showman gave was using carved homasote, which is made from recycled newspaper and non-VOC adhesives, to make faux brick and stone facades, rather than vacuum-formed plastic panels. Not only is the plastic a petroleum-based product shipped from overseas, but it releases toxic fumes when heated in the vacuum former. Homasote comes from a company in New Jersey, so it only has to travel a few miles. The results look the same, and the costs are comparable. By showing the designers what they can achieve with more sustainable and less toxic materials, it makes it easier to convince them to accept them.

Fake Food: Making Edible Replicas

They used to solve this problem in the breakfast scene of “The Duke of Killiekrankie” by having the food made of candy which would melt rapidly in the mouth, and so not interfere with enunciation. The hashed brown potatoes, for example, were nothing but spun sugar, browned, which looked substantial enough to the audience, but melted away almost as soon as they touched the tongue.

– The New York Times, April 1, 1906.

I have previously written about making inedible fake food. A props person may also have to make edible fake food. What is edible fake food? Say a character needs to eat a peanut butter sandwich, but the actress playing that character is allergic to nuts; you need an edible replica of peanut butter that contains no nuts.

Props people make edible replicas for a variety of reasons. Most common is the above-mentioned allergy issue; before planning a meal, you (or your stage manager) needs to find out what the actors are allergic to, and any special dietary needs. An actor may be vegetarian or keeps kosher. Besides allergies and diet, actors avoid other types of food while on stage; milk and cheese, or sugary drinks, tend to affect the vocal chords in ways which many actors dislike. A prop master’s greatest challenge is when he or she needs to serve a massive edible banquet, and an actor is vegetarian, allergic to gluten, and lactose-intolerant.

Another reason to make edible fake food is cost. Characters on stage may chow down on what appears to be hundreds of dollars of caviar in a single scene. You need a more cost-effective solution if you want to keep your budget under control. In a similar vein, certain foods may be time-consuming or complicated to prepare. Remember, your running crew needs to prepare the food before each show in addition to their other pre-show duties, and if your production has matinées, they may have an even tighter schedule between the two shows. It’s usually better to microwave a turkey substitute for thirty seconds than to roast a real turkey for four hours.

Third, the food on stage may require special properties which the real deal does not possess. A common example is when a director wants the characters to eat ice cream, but does not want to see the ice cream melt during the scene. It’s a tricky feat to pull off under those hot stage lights.

Finally, an actor may need to eat something which is normally not edible. Edible flowers are commonly called for, as well as paper notes. Be prepared for anything.

It is important to keep the food preparation area clean, which means separate from any work areas. If you keep a stock of preparation dishes and utensils, these should be kept separate from your regular stock of kitchen props; you don’t want to prepare your food in a dish that was painted with a toxic paint for the previous show. Likewise, the food needs to be stored properly in between shows, especially if you buy a whole bunch at once for multiple performances. It should also go without saying that you should not attempt to reuse uneaten food from one performance for the next one.

Creating edible food is a little bit sculpture, a little bit painting, and a whole lot of creativity. It’s good to develop a sort of “base” of materials which are readily available, easy to work with, and can mimic a great deal of foods. Bananas, breads, and food coloring have been some of the more popular bases for props artisans for well over a century.

Bananas can be mashed to imitate a great number of foods, such as cream or ice cream. With the right coloring and toppings, it can even substitute for meat or fish. When sliced lengthwise, you have a decent white meat substitute for chicken. Yogurt and cottage cheese work in a similar vein, but because of the milk content, they are less-commonly used.

Bread can take on a variety of shapes. Brown bread with the crusts removed and cut to the proper shape can simulate chops and roast meat. I saw the head of properties at the Walnut Street Theatre create a very convincing Salisbury steak each night with just a slice of pumpernickel covered in cold canned gravy. Switch the gravy with fruit glaze or some other red jelly and you have a slab of raw meat. A whole loaf with the crusts removed can be shaped into a number of different forms. If you use a loaf that is at least a day old, you can even carve it somewhat.

Tofu is another kind of base which can be built on for any number of fake edibles. It has the advantage of being vegan, and in some cases, gluten-free, so it’s a great choice for tricky eaters.

Food coloring adds greatly to your repertoire of faux food creation tools. It can be tricky to match the color and opacity of your intended goal; luckily, everything is edible, so you can eat your tests and samples. Specialty baking shops will stock a greater range of colors and sizes, so you don’t have to try to create every single color with those tiny bottles of red, yellow, blue and green. You can also find culinary colors in spray cans, which are a boon for the more artistically inclined.

Fruits are a friendly substitute for many foods, and can be tastier for the actors than old bread covered in cold gravy. I used a fresh grape and a dried apricot for my appetizers in Timon of Athens. I’ve also heard of shows which used half an apricot for an egg yolk and a pared apple for a raw turnip. Watermelon with some brown food coloring makes a convincingly juicy slab of raw meat. Dried fruits such as prunes and apricots can be cut up, shaped and squished to resemble a variety of things, and are especially handy when you have that large banquet scene that requires a variety of edible colors and textures to appear sumptuous.

Sausages and other imperishable meats serve a similar purpose as dried fruits. With the skin removed, they can be sliced and carved to mimic all sorts of appetizers and side dishes.

Fake edible food is a great exercise for students and interns because it forces them to distill an item (the real food) to its most recognizable characteristics, and then come up with a simple and economical replication of those characteristics. It makes them think about the constraints of a show, such as preparation time, cost per show, shopping time, etc. Finally, most people do not create fake food in their spare time, so they can’t fall back on familiar materials and methods, such as carpentry or foam carving.

A knowledge of cooking, baking, and food preparation is helpful, as it can help you learn how to thicken or thin various sauces and liquids, or give you clues how to cut and shape different foods. A trip to a culinary or baking store is great as well, as you can find all sorts of icing bags, cookie cutters and food-safe molds to help you out. I read about a production in 1906 which used a mold of a chicken to bake a sponge cake that could be carved and consumed on stage. Now that’s a tasty trick!

Review: Health and Safety Guide for Film, TV, and Theater by Monona Rossol

The Health and Safety Guide for Film, TV, and TheaterIt’s difficult for me to write a review about the Health and Safety Guide for Film, TV, and Theater (Second Edition) by Monona Rossol for several reasons:

  1. The information inside is mandatory.
  2. No other book is dedicated to this information.
  3. Monona Rossol has been teaching health and safety to theatres since at least 1986 and is uniquely qualified to write this book.

So rather than a review, this is more of an introduction about being aware of your own health and safety, and an encouragement to read this book and act on the information contained within. This goes for those working professionally, as well as the growing number of hobbyist prop makers (I would say especially for hobbyist prop makers).

I’ve attended Monona’s safety seminars three times, and even with this book, I am still learning about the hazards we face in our line of work and the precautions we need to take. Luckily, she uses a very factual and empirical approach with this book. Rather than present her personal opinions, she discusses what the laws and regulations are. She will also present the various studies done where she feels the laws don’t go far enough in protecting workers. This is perhaps one of the more striking lessons to take from this book or her seminars; as stringent as we may feel OSHA is, the dangers we face remain woefully understudied, and manufacturers have great latitude to push untested chemicals on the market or provide misleading safety claims on their labels.

You’ll notice the mention of OSHA above. This book is very much grounded in the legalities of working in the United States. Though she may occasionally mention regulations in Canada, the UK or Europe, her focus remains firmly enmeshed in US law. Unfortunately, there is no real equivalent to this book outside of the US. All is not lost for my international readers, though. Since US laws protecting workers are among the most lax in the developed world, this book can be seen as presenting the absolute minimum guidelines for protecting yourself on the job.

While the book does deal with electrical safety, shop safety, fall hazards and other areas of physical danger, the majority deals with materials and chemicals and the less-understood danger of chronic exposure. We all know that you should avoid chemicals that could instantly kill you if you accidentally breathe them. What is far less understood is the result of your body somehow absorbing a myriad of chemicals and products throughout the day and over the years you are in the workforce. Some of these can live in your body for years, reacting in unknown ways with all of your genes and the other chemicals present in your body. Steve McQueen died from mesothelioma at a time when asbestos was used frequently in the theatre and film industry for painting and prop making; what are you being exposed to?

If you’ve never given thought to any of this, this book will be overwhelming in the information it provides. You may think we are safer these days with our stronger laws and new products. After all, lead paint only comes from China and we don’t use crazy materials like Celastic anymore. But as Monona points out, lead has only been banned in indoor house paint; it can still be found in any number of industrial paints. Some filling materials and putties were still being taken from a mine which contained asbestos as late as 1998. We are also exposed to far more chemicals on a daily basis than our fore-bearers in the past. Every one of us is already carrying a certain amount of mercury, dioxin, PCBs and countless other chemicals in the tissues of our body (known as our total body burden); scientists estimate we carry as many as 700 contaminants regardless of where we live in the world. Any additional chemicals we add from our work place enter that toxic soup and can have all sorts of additive or synergistic effects. So it’s even more important for us to monitor what we use than it was for our grandparents.

This second edition is long overdue; the first edition came out over 11 years ago in 2000. Monona includes many of the important changes to the laws as well as advancements in the science behind the effects of the chemicals (both of which have a lot owed to Monona’s own tireless work), and the addition of new types of products in the marketplace, such as nanoparticles. Unfortunately, the through-line remains the same: companies don’t want to spend money on safety training, manufacturers add more toxic products to the market, scientists can’t afford to study even a small percentage of their effects on the body, and governments refuse to pass stronger laws or give their agencies the power to enforce existing ones.

Until all that changes, though, we have this book. Read it and use it.

Shams in the Theatre, 1880

The following article comes from The Daily Dispatch, Richmond, VA, December 2, 1880. I added a few paragraph breaks to make it a little easier on the eyes.

Shams in the Theatre

The Ingenious Work of the Property Man–Remarkable Effects Produced with Cheap and Common Materials.

(New York Tribune.)

Theatrical properties, so called, include all things placed upon the stage except what are painted as part of a scene by the scene-painter. Urns, vases, flowers, pictures, pianos, carpets, rugs, furniture, and all ornaments are “properties.” Besides these, all articles used by the actors in the performance of the play, such as canes, cigars, pistols, clubs, knives, pocketbooks, money, and other things of similar nature are properties. The property-man of a theatre has a responsible and arduous-position. Upon him depend many of the important points in a play. The check for $30,000 that saves the impecunious artist from an untimely grave; the secret drawer and hidden will, which, when revealed, restore the wandering heir to his rightful inheritance; the marriage-bell that hangs above the heads of the happy lovers in the fifth act; and the pitiless snow through which the shivering blind girl wanders singing her mournful songs, all are prepared by the property-man. Sad is the lot of that luckless wight who forgets to load the pistol with which the desperate villain is slain. The property-man is provided by the stage-manager with a complete list of the properties needed for each scene, and it is his duty to see that they are prepared and in their proper places before the curtain rises.

In the earlier days of the drama it was customary for the property-man to make all his own properties. Continue reading Shams in the Theatre, 1880