Set Construction at MCHS
From Mchs Theater
This article describes set construction basics at MCHS. The scene shop was originally equipped with a dozen or so cordless drills/screwdrivers. At the time, it seemed like an extravagance, since one could buy a dozen hammers for the cost of just one cordless drill. The benefits became soon became obvious:
- Set construction is less tiring, and since less upper body strength is needed (vs. hammer and nails), more people can participate
- Strike is much faster and easier, and there is less damage to the wood, enhancing reuse
- Screws are stronger than nails, so less of them are needed for equivalent strength.
Although there is certainly a variety of structural materials used in MCHS sets, the majority fall into a handful of categories.
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Structural wood
Three sizes of "stick' lumber are in common use
2 x 4
A "2x4" is really 1 1/2" x 3 1/2" and is made of either spruce, pine, or fir, with pine being the most common. MCHS typically buys them in twelve foot lengths, although frequently eight foot or 93" sizes are on sale and we'll do a buy of those. Typical uses of 2x4's are for platform legs, heavy duty framing, bracing, and other application requiring a strong and fairly stiff structural member.
2 x 6
A "2x6" is really 1 1/2" x 5 1/2" and is made of either spruce, pine, or fir, with pine being the most common. 2x6's are almost exclusively used in MCHS for outside edge of stage platforms. A properly build 4' x 8' platform built with 2x6's only requires legs at the corners, while a corresponding platform build with 2x4's should have additional legs at the midpoints.
1 x 3
A "1x3" is 3/4" x 2 1/2" and is almost always pine. Occasionally, we'll get a good buy on "1x4" so be sure and measure first if the exact width of the board make a difference in what is being built. 1x3's are used for the framing members in flats and other light duty applications.
Sheet goods
Two types of sheet lumber are in common use for MCHS construction. They are both supplied in 4' x 8' sheets.
Luan
Luan is a thin (1/4") wood used for facing, mostly for flats or as skirting around legged platforms. Luan's advantages are that it is smooth and relatively cheap. It takes paint well without surface prep. On the minus side, it splinters very easily, warps if wet, and does not take point loads well. A properly built luan flat is very durable and can be used again and again.
Decking
Decking refers primarily to 3/4" inch plywood used to provide the walking surface for platforms. 3/4" ply is very strong and makes a very rigid and sturdy platform.
Other materials
Smaller sizes of stick lumber are sometimes used for decorative items like fence pickets, props, etc. Occasionally, platforms will be covered with Masonite or MDF if an extra smooth surface is needed. Both Masonite and MDF are manufactured from wood fibers and do not have wood grain like plywood or luan. They also have a high content of a binder (glue) which dulls saw blades quickly. These manufactured materials are not very rigid or strong and require appropriate bracing.
