Tag Archives: sewing

No-Sew Pillow Video

No-Sew Pillow Video

I often neglect the fabric side of props on this blog, simply because it’s more challenging for me and I avoid fabric projects as much as possible. Of course, we props people need to develop all our skills, not just the ones we are interested in. So I’m sharing this video I found of a fabric project that even I can pull off: a no sew pillow. With just an iron, hem tape, an iron and a thrift store pillow, your set can have pillows that fit the design of whatever show you are doing.

Good Friday Links

David Neat starts us off with making smooth shapes from Styrofoam. He’s dealing with the real-deal Styrofoam here, not that white bead foam stuff. And sure, this article is over a year old, but it has some really useful techniques.

Bill Doran has a helpful video on adding rust to your props. Ninety percent of the time when I show a completed prop to a designer, they say, “that’s great… once we age it down a bit.” Knowing how to weather, age, distress or generally tone down props is an essential skill for a props person, and adding rust is one of the ways to do this.

Make Magazine takes a look at some Maker-Friendly hardware stores from around the US. It’s a fascinating look at the vast array of materials a store might choose to stock, as well as a sobering reminder of how awesome hardware stores used to be to those of us whose only local options are Lowes and Home Depot.

I covered some basic stitching for fabric in my Prop Building Guidebook, but if you get into embroidery and ornamental stitching, there is a whole other world of ways to manipulate needle and thread. Tipnut has some great vintage illustrations of ornamental borders and the basic stitches to make them happen.  It’s a relaxing project for when you are bored in tech and the designer wants the napkins to be “fancier”.

Finally, here is an article called “The Most Important Lessons in Woodworking“. Robert Lang uses his experience cutting plugs as a lesson in woodworking in general, and I think this lesson can be expanded out to prop making in general. It’s not just about how to use specific tools or techniques, but how to approach your whole project in the most efficient and easiest manner possible.

 

Daenerys' chest of dragon eggs

Replica Chest from Game of Thrones

Usually, I am building props for a show or production I am working on. I rarely have time to work on my own projects. However, someone was interested to see if I could replicate a chest from the television show Game of Thrones. Now, I have nothing to do with the show itself, but it sounded like an interesting challenge to see if I could match something I could only see on screen. There wasn’t anything particularly tricky about this chest; it just had a lot of pieces and parts made of an assortment of materials, and some very time-consuming detail. For those who watch the show, this is the chest given to Daenerys in season one, which held her petrified dragon eggs.

I shot video of most of the build along the way and somehow edited several months of work into seven and a half minutes of video, giving an overview of the process.

If you are interested in more detail and photographs, read on!

Daenerys' chest of dragon eggs
Daenerys’ chest of dragon eggs

The first part was the box itself. I worked out a quick mock-up of the whole piece in SketchUp to figure out the sizes and proportions of all the parts. I decided to use ash on this because it is hard and strong like oak, but I really hate working with oak. The grain pattern of ash was also a better match to the real chest than oak. We have a great local hardwood store that I visited, and I was able to find boards wide enough that I could build every side (except the top) from a single width of wood. The bottom was a piece of oak plywood.

Wooden box
Wooden box

The chest has a number of areas covered in metal. I bought a sheet of 22 gauge steel and cut it up by hand with my airplane snips. I used my sheet metal bending brake on the corner pieces, while the rolled-over edges of the top pieces were bent by hand with sheet metal tools and pliers. Although I could have saved time by making these out of plastic and painting them to look like metal, the “roll over” parts would have ended up too fragile; on the very corners, you can see how thin the metal is, and any plastic that thin would flex whenever you touch it. The hasp on this chest also rests against a metal section, so it gives that solid metal-to-metal sound every time you open and close the lid.

Sheet metal layers
Sheet metal layers

The most time-intensive part was the applied decoration. I used styrene plastic for this because using actual brass would have been prohibitively expensive and time-consuming, and a cheaper metal would have required just as much paint to match the appearance that the added labor was not worth it. I began by going through all the scenes in the TV show where the chest appeared and pulling out as many clear screen shots as I could, and then manipulating them in Photoshop to get a straight-on view. I scaled them up to full-size, printed them out and cut the pieces into patterns to trace on the styrene. Some parts of the design needed to be extrapolated slightly because I never got a clear view, but because it was symmetrical, repetitive and followed a certain logic, I was pretty confidant with how well my version matched the original.

Patterns and reference
Patterns and reference

Nearly every element was made of at least two layers of styrene, so after cutting the several hundred pieces out, I began gluing them together using model airplane glue. I did not attach them to the box just yet, but I did lay them out to test fit everything.

Unpainted decoration
Unpainted decoration

With all the pieces ready, I began painting. They received a base coat of hammered silver spray paint, followed by a heavy dusting of hammered bronze spray paint. They would receive more paint later on, but at this point I began attaching them. Working on one side at a time, I first laid every piece out and used careful measurements to make sure everything was symmetrical and evenly-spaced. I then traced every single piece in place and labeled them by number before taking them off. I did some tests and found contact cement gave the strongest bond, though that meant I had to apply it to both the plastic piece and the box, and I could not apply it to the parts of the box where the wood was visible, so I had to carefully paint it within the traced outlines I had made. Luckily, the contact cement bonds almost instantly, so I could begin working on another side after one was completed.

Spray painted pieces
Spray painted pieces

The inside of the chest was leather, though I went with a slightly-more processed version which was already finished and could fit through my sewing machine. I stitched all the pieces together first, and then attached them in as a single unit. I used a bit of spray adhesive to keep them from shifting around, but they are mostly held in place with the visible upholstery tacks. I pre-drilled holes for the tacks so I could make sure the spacing was even, and also because the ash was too hard to just hammer the tacks straight in.

Leather interior
Leather interior

I found hinges online that were so close to the ones on the real chest that I wouldn’t be surprised if the prop makers bought theirs from the same supplier. I could not source the hasp though, so I had to fabricate it from scratch. I started with a basic hardware store hasp and cut notches in the edges. The tip was cut from another decorative gate hinge. I cut a bar of steel to length and bent a curl in the edge, than plug welded the whole thing together from behind and ground the welds flush to the surface.

Pieces for the hasp
Pieces for the hasp

With all the pieces in place, all that was left was some painting and sealing. The top layers of all the decoration were sponged with a lighter brass color to set them off, and the whole chest was washed down with some dark browns and blacks to age and weather it. Finally, everything was coated in a clear satin Polycryclic.

Pristine and unsealed chest
Pristine and unsealed chest

I hope you enjoyed this as much as I did!

Full-length pheasant near completion

A dead pheasant for King Lear

In our production of King Lear, which is in its last week of performances here at the Public Theater, one of the first props we knew we needed was a collection of dead animals for when the men return from hunting. I knew from doing Timon of Athens last winter that we had nothing in stock, no one in town had anything we could rent or borrow, and you can’t just go out and buy them, so I began trying to make a pheasant.

Developing a full-scale pattern
Developing a full-scale pattern

I began gathering research images and working out a pattern. I worked out the size by looking up average heights and lengths of pheasants, and from photographs where pheasants were next to people and other objects of known sizes. In retrospect, I should have looked at more pictures of dead pheasants; a pheasant has a really long neck. In most photographs of pheasants in action, the neck is contracted so the head appears close to the chest. When the pheasant is dead and hangs limp, the neck is actually a good five to six inches long. You can see I was drawing a bird with a contracted neck which left my dead pheasant looking stiffer than a real one. Ah well, now I know for the next time I have to build a dead pheasant.

Pinning and stitching the seams
Pinning and stitching the seams

Once I had the pattern, I cut pieces out of muslin and began stitching them together. I left one side open so I could fill it with sandbags for weight. Some of the stitching was a little sloppy, which was okay because the whole thing was going to be covered in feathers and small imperfections would be obscured. Continue reading

Pachi the stuffed kitten

Stuffed Kitten from Recycled Fabric

I’ve posted a new Instructable on making a stuffed kitten; that makes a whopping total of two since my wooden ratchet noisemaker last year. The cat wasn’t a prop for a show, but I thought I’d share it for two reasons. First, I made it out of materials from a previous show that would otherwise have ended up in the trash. Second, our prop shop had just gotten our first sewing machine. Before this, our artisans had to go to the costume shop to work on upholstery and making things out of fabric. I’m not much of a soft-goods person; in fact, the only actual item I’ve ever made out of fabric is probably a sweater in my seventh-grade home-ec class. I took this new acquisition as a chance to practice a must-needed prop skill; you’re never too old or awesome to start learning something new.


Making an upcycled plush kittenMore DIY How To Projects