BY GEORGE LEDO
Now and then I see a post in the Educational Theatre Association (EdTA) open forum regarding ideas for a new scene shop, or tools, or something related, so I decided to do a few pieces here. This first one is about scene shops in general, the second will be about work areas and storage of tools and equipment, and subsequent ones will be about related subjects.
First off, a scene shop is nothing more than a dedicated place to build custom items which may be made of wood, plastic, metal, or other materials. The process, the tools, the ideal layout, and everything else are pretty much the same as in any other custom shop that specializes in these materials, the main difference being that the scene shop is used to build scenery instead of cabinetry, furniture, or other products. So we’ll look at a scene shop with that perspective in mind.
Workflow and layout
Like in other shops, the workflow in a scene shop is very straightforward: the raw materials come in “at one end” and the finished products go out “at the other end.” In between, the materials get stored temporarily, get cut to size and otherwise worked, get assembled, and get stored temporarily again until they get painted. Then they get painted, and, finally, they move onto the stage to get installed. Later, after the show closes, the pieces may come back and get disassembled.
And there are usually two or more projects (individual pieces of scenery) going on at once.
So, ideally, the shop layout should reflect the workflow: the raw material comes in at the loading dock end and the finished pieces go out the other end onto the stage. This suggests a long skinny room, but of course most scene shops aren’t built this way (most of the ones I’ve seen are either square or close to it). The idea, however, can still work with a little planning and/or rearranging of the existing equipment.
If you already have a shop, a good way to see if it is laid out with workflow in mind is to observe the construction crew during a typical show. How often do they have to move materials and piece parts from one place to another and back again? Some movement is of course inevitable, but (for instance) if you have to bring new plywood sheets to the back of the shop for storage and then bring them to the front again because that’s where the table saw is, you may want to consider a little re-arranging. Or if the paint area is at the back of the shop and the stage door is at the front, or if you have to run an obstacle course to get to the panel saw or radial arm, or if the best place for assembly is taken up by a large stationary power tool. But you get the idea. And don’t laugh: I’ve seen all these instances and many more.
One thing to avoid whenever possible is storing scenery, props, or other items in the shop. Unless the room was deliberately planned large enough to have dedicated areas for storage, what often happens is that it becomes a warehouse and leaves very little space for work. I’ve seen a few (large) shops that were so full of stored stuff that there was hardly any place to work; even the work tables were piled with props and other items, so layouts had to be done on the floor — and there was very little of that.
A major factor to consider when planning a shop is flexibility. Some pieces of scenery are fairly small and others may be huge, and sometimes you get some of one and some of the other, plus everything in between. The best way to deal with this is to dedicate a large open space strictly for assembly, and then to put as many of the power tools as possible on casters so they can be moved out of the way if necessary. I’ve seen a few shops where the table saw and other large tools are in the worst possible places, but they can’t be easily moved due to the placement of electrical outlets and dust collection systems. Their placement also cuts down on open space for assembling large pieces.
I’ll go more into this in the next two posts.
There are lots of resources available on how to set up a wood shop: books, magazines, online articles, and videos, and they are great for generating ideas; some even show actual or suggested floor plans and designs for storage cabinets. I have a workshop in my garage (I don’t build scenery or props at home, but woodworking has been a hobby since high school), and I consistently find great tips and ideas in these resources. Some of my favorite ones are listed in the Resources page of this blog, and there are lots more. I’ve seen a few pieces on how to set up a scene shop too, mostly in the older books, but unfortunately they were either very specific or are totally outdated