Joining the Pieces |
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The first step in building your flat is to construct the frame. Our bill of materials calls for 1x2's. You can use 2x2's, but we've found these to be heavier than needed and don't use them except in limited circumstances where we need a particularly sturdy piece. Also, our bill of materials specs lumber that is pre-cut for length; obviously, your first step will be to cut standard size pieces to your own specifications. We've specified clear pine 1x2's. The main thing is to use high
quality, light weight wood that is straight! This can't be overemphasized. When you're working with flats that
are even eight feet high, bending and warping are extremely noticeable, particularly under stage-lighting. |
| After you've cut your frame pieces, you'll need to fit them together.
We highly recommend that you do this with dado cuts. Mark your vertical pieces at top and bottom and at appropriate spots
for the interior cross-pieces (we use three feet from top and bottom in this example). Make dado cuts that are just wide
enough to accomodate the 1x2 cross-pieces (1 and 9/16 inches) and set your blade to cut deep enough to "match"
the corresponding cut in the cross-piece (3/8 inch). Experiment with some scrap pieces first.Once you've made all your dado cuts (both vertical and cross-pieces)
lay them out on a flat surface and use a carpenters square to align your frame. You should be able to simply glue the
pieces together, although some folks add a screw at each joint (remember to drill a pilot hole to avoid splitting if you
do this). Let the glue dry (preferably overnight) before attempting to apply the covering. |
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