12th November 2011
Arrival Time: 8.30am
Arrival Time: 8.30am
Rhiannon and I arrive on set at 8.30am, as Richard was running late due to traffic we discussed with John what to do to prepare, and we decided to clear the chairs from the acting area so it was clear to build.
The Studio Theatre at the Start of Day One
Area ready to start construction
When Richard arrives we discuss our plan of action as to what we are going to build first, which has differed from the schedule we worked through with him the previous week! What we are going to start with is the whole of the back section, the two longest horizontals (at over 4m long) and the detailed A frame.
Richard sets up a couple of steeldecks as a work bench, and a few tables mounted with some old theatre flats for the cross saw.
Richard teaching Rhiannon how to safely operate a Cross Saw
The way we are going to construct each beam is to take two pieces of 6 x 1 timber and at an interval (varying between different pieces, but on average every metre) put in a supporting block of 150mm x 100mm to support the beam and make it structurally solid and strong. We drilled a pilot hole in the 6 x 1 to prevent the timber from splitting then used 2" screws to stitch the pieces together.
Rhiannon attaching the supporting pieces
Once both sides were attached the the supporting mid-sections, we stitched a top piece on, drilling into both the timber and the supports. As the timber was a little wider than we originally though, we had to split the difference across both sides of the beam as it would not lie flush.
Here is a rather fetching picture of me and a cross section of a beam; see how much I'm enjoying myself?!
Showing the inside of a beam.
Each beam then needed a draw knife running along the top piece to take the edge of it and to make it look "rustic". Richard advised us to not take too much off or it ends up looking a bit Disney and over-done. Subtlety is key.
Me using the draw knife to remove the edges.
A piece showing the intervals for support and structure.
We worked quickly, and before we knew it most of the back section had been made. We had to slightly deviate from the design and add some 355mm supporting sections in between the top beams as seen in the next photograph.
The two longest sections, and nearly all of the cross in the centre.
This photo also shows how we stitch the pieces together with a brace on top for extra strength, as well as inside the pieces with "Super Screws".
When we were doing the angled edges, we looked on the drawing and took the measurement from each side, then Richard hand sawed the angle in. As I was drawing the angles onto the timber I had to ensure that I got it on the right side!
When it came to putting in the long "A Frame" pieces, Richard guessed that they should be at a 45 degree angle. Really, I should have put the angle on my cad drawing, but I didn't think that we would need it. Silly. As you can see from the picture below, the angle was wrong, so Richard had to re-saw it. It wasn't a massive problem, just a problem that needed solving.
Now it fits!!
Once we made all the pieces, we stitched them together and we were proud of ourselves. I didn't think that the process for the structure would be so quick!
When we lifted the structure we realised it was far too heavy, and I had to point out that on the plan view of the structure, the A frame was actually in front of the back structure, not underneath it. We had to re-work out how to then put the supports in, but it was all good, nothing too complicated! We detached the top pieces so the A frame was a separate entity.
Rhiannon was very happy with it. As you can see!
I really enjoyed my first day; I learned how to use a power drill, an impact driver for the screws, a cross saw and a normal hand held saw. I was impressed at how quickly we made the back structure, and I knew that Day 2 we'd be even quicker! When you see a model box, you know its going to be four metres high, but you never realise how high that is until it's up! It's so exciting to be part of a build, and I feel like I've found something I am good at, and I enjoy. The realisation from 2D to 3D is amazing! It's also a good feeling knowing that the drawings I have done are being used, and are important.
