This isn’t an official KWLT document - it is my recommendations from my experience doing tech for KWLT and other shows.

KWLT stocks a number of “building blocks” for set construction. To whit, KWLT stocks a good number of 4×8 flats, 2×8 flats, 4×8 window flats, 4×8 door flats, 4×8 risers, a few odd sized risers, assorted stage jacks, stage weights, two platform kits (to turn risers into 5′ platforms), two stair units (5′ high, 7′ long, 2.5′ wide) and assorted stage jacks. Look to see what already exists before building your own! When possible, build reusable components to save future shows the effort of duplicating your work.

Definitions

• Flat - a vertical piece of stage construction. Used to build walls. May be pierced for doors or windows or simply blank wall.
• Riser - a low platform, typical 4″ or 6″ high
• Platform - any platform higher then a riser. KWLT has two kits that will turn a riser into a 5′ platform
• Stage Jack - A brace used to keep a flat vertical
• Stage Weight - A weight, either a sandbag or lead or steel bars, used to hold a jack in place
• Box Set - A set that forms three sides of a room, with the audience looking in the fourth side. Common when a play takes place indoors, especially when the set is intended to be realistic

Construction Tips

1. Talk to the producer of the show before spending money!
2. If you plan on using KWLT stock (which is encouraged!), talk to the KWLT Tech Director. He’s at td @ kwlt . org - he can let you know what’s available, give information on how to do things and point you at other resources you may not be aware of.
3. When joining these elements (and custom made ones) into a set, use screws. The set will have to be struck when the run is over and screws allow you to reuse the items.
4. When a screw is present on a surface that will be painted, cover the screw with masking tape - when the set is struck, the screw head will not be full of paint
5. Where two flats meet, cover the seam with a strip of wide masking tape (as wide as you can find). When painted over, the seam will disappear. This is a cheap and easy version of ‘dutching’ the flats (the pros use torn paper/fabric and paste)
6. Use hinges to join flats together. Join them on the back whenever possible. Use short screws
7. Nails should only be used for permanent construction. Avoid them wherever possible. Screws are better - they are faster (given the universality of screw guns), stronger and they can be removed without damaging the flats or pieces, saving them for reuse.
8. Jacks can be attached to flats with hinges as well and are weighted in position with sandbags or other weights.
9. Take advantage of low pipes and attachment points to reinforce the set. Most of the theatres KWLT plays do not allow attaching anything to the floor. Be aware of this and plan accordingly. St Jacob’s Church Theatre, for instance, has a low pipe each side of the stage that can be attached to when doing a ‘box set’ - I generally run a short length of 2×4 from the furthest stage right/stage left flat up to it and attach using flexible metal tape
10. Before arriving in the theatre, plan out the set in as much detail as possible. Obtain a sketch of the theatre before hand. Have a plan and think through the plan, figuring out what should happen first. If you are running a build, people like knowing you already have it sorted out
11. Arrive with everything you’ll need - if you have a plan, you should be able to estimate materials pretty well. Pick up 5 or 6 extra 1×3s - at $1.76 each, that’s ten bucks well spent. If you have everything you need on site already AND you have a plan, tech weekend happens much faster and everyone is happier
12. Remember to schedule your time - set building isn’t the only thing happening on tech weekend. Lights may need to be hung or focussed, tech rehearsal or cue-to-cue may need to happen. Coordinate the tech weekend schedule with the tech director, the director, the lighting designer/electrician and the stage manager - and anyone else who might need access to the stage that weekend.
13. Before starting construction, start with a clear stage and use a tape measure to mark where set pieces will sit. This will probably be your last chance at having clear and easy measuring, so take a bit of extra time and get it right. Use masking tape or stage tape to mark the spots. Once the set is masked out, show the director, stage manager and tech director - this is a better time to find out that the plan won’t work then after things are up!
14. Of course, an even better time is well before tech weekend - get your plan on paper and get it to the rest of the creative crew! Check out the info on Sketch Up on the main theatre page on my website, to see another way to show a plan to the rest of the cast and crew.
15. When building your set, start with pieces that will self-support. If you have flats that form an angle, they are a good starting spot as once they are hinged together, they will stand upright.
16. If multiple pieces self-support and if you have enough people, start groups at different spots and have them work towards each other. In general, theatre sets are fairly light and a reasonable sized crew can move things so that they meet exactly
17. Use 1×3s (or 1×4s) for most elements of the set. You can cover a frame of 1×3s with luan (see the Build A Flat file) for a light, solid looking piece.
18. Only use 2x stock (2×4s, 2×6s, etc) for pieces that must support weight or has other strength requirements. 2x stock is heavier and more expensive then 1x stock