Set Build Day 2

Matching up top and one side of prosc. to ensure we cut at the right angles/ the pieces meet correctly. 

Cutting the mdf to create correct sized cladding. Richard said  that idealistically he would have pre cut all cladding pieces  so once the frames were made  they could be stapled on easily. However, in this instance he did not have enough time.

Top piece fits! Ready to be screwed in.

This piece was reinforced afterwards with a timber framework as as it is so small it is likely to snap off during the  move to the Ocean Room. 

Using strips of timber to mark out the frame underneath to screw cladding into, this ensures a secure hold between cross and cladding and allows for less mistakes drilling into the cladding alone and hence making less holes in my lovely set!

Reverse view of entire Prosc clad showing the reinforced joins and carefully considered framework  needed to ensure it is safely and sturdily built.

Larger pieces of timber are added at joining points for when the Prosc is erected. This reinforces the join and will make it extra strong when fixed together with super screws.  

Adding the curtain rail baton for the curtain pulley system. Richard and I measured the distance between  the floor and the rail many, many times at different points along the Prosc to ensure it was parallel to the ground. The illusion of all the angles in the structure were very deceiving making it hard to tell by eye if it was correct. The final positioning looked completely incorrect but the tape measure confirmed it was in the right place!

All Pallets made and laid out in their format in the design. 

Making masking flats for sides of Prosc, these will also act as support and braces for the Prosc structure.  This is the frame work in its initial stage for which I drilled the holes for screws and screwed in the middle batons. Richard made sure that in each case the wood join was flush and was not twisting the wood as once this is created in the structure it can't be got rid of.

Corner supports to maintain it's shape/stability.

Covering the flat in black molten, serge is also appropriate.  Wool works best as it is dense and can be stretched to the right tension...which was lucky in this case as the fabric was about 3 inches too short however, with perseverance and a lot of stretching Richard made it work! 

Second side stapled - need to work from the middle outwards and really pull the fabric to its maximum  tension to staple each section.

Adding more staples to the corners so it holds its shape nice and tight. The smaller edges are done last as they are easier to pull taught. Richard also explained how posture is important with doing this task as I was bending over a lot to put in staples which would really hurt your body if you were to make 200 a day which they do, you need to stand nice and upright. He also said that where there are creases the fabric needs to be turned over as this is often visible on black.

The flat I made on top where the fabric is being trimmed away. John showed me that putting the staples in at an angle makes them hold better. I am very proud of my first ever flat, according to Richard I'd get the job!

Prosc structure with curtain baton and bracing. 

Amber cutting the styrofoam for the stream carving. I wanted to get this finished prior to Debs arrival tomorrow as she said it could take a long time and I will be off site at the costume parade all morning.

Cutting out neccessary pieces. We decided that it was best to add this foam  entirely to the top corner to be collaged as this change in height made from wood would add to much weight. This task I was very careful to make sure that the styrofoam didn't come proud of the join so they will meet correctly when the set is assembled.

Marking out which pieces are collaged and which are to be carved so it is clear during my absence tomorrow.As Ellen was present and will be helping with the set painting tomorrow I explained this to her so she could get it started first thing. I would have liked to have started carving this evening but there simply was not enough time.

Set - all ready to paint at the end of day 2!