For L’Etoile, I created a case for the peddler, Lazuli. The case is covered in faux leather and trimmed in stained wood with straps so the actor could carry it like a backpack. The final version differed drastically from the initial concept, after they played with different styles and methods in rehearsal.
Here the case is pictured in its backpack position.
Inside, the lid was lined with decorative paper and compartments were built to separate his different items.
Lazuli is pictured above wearing his case.
For Volpone, I built four identical Savonarola chairs. The designer liked the Savonarola style, but wanted to contemporize them to match the look and feel of the overall design.
This chair, by Design Toscano, was one of the research photos showing the traditional Savonarola chair.
This is a designer sketch showing how he wanted to contemporize the style.
Based on the research pictures and conversations with the designer, I drew a 3D model of the chair using Google SketchUp. Drawing the chair in 3D allowed me to virtually construct each piece before cutting a single board.
The most time consuming part of the construction was cutting the legs. Once I gridded, cut, and sanded the template, each leg had to be traced, cut, and flush-trim routed to size. The seat, arms, legs, and back were cut with the same process.
After all the pieces were cut, they were base coated. The legs and seat pieces were then assembled using 3/8″ threaded rod through pre-drilled holes at the joints, capped on each end with acorn nuts.
Pictured here (upside-down) is the chair with the legs fully attached to the seat.
The arms and feet were attached next.
And finally, the back.
The four chairs together, before final paint.
Two of the completed chairs, painted gold to match the set, each with a custom pillow.
For The Illusion, the designer wanted wireframe umbrellas during the rain sequence. I experimented with several options including modifying traditional umbrellas, but building them from scratch was the best solution.
This is the research I was given for the look of the umbrellas.
ch of the 8 spokes was welded to the center rod, then bent down around a wooden jig. The curved pieces were then welded in between each of the spokes to mimic what would be the edge of the fabric.
The shaft was then inserted into a pre-drilled hole in an existing umbrella handle and fastened with two sheet metal screws.
After spray painting them to match the hoop skirts, they were complete.
This 3 ft. by 8 ft. banquet table was built for Falstaff.
This is the main research from which I built the banquet table. The designer did not want the center two legs, however.
To cut the detail, I built a router jig which lock the board at a set interval, allowing me to plunge-route the cove.
Shown here is the table frame, before the lid was attached.
As I completed the table, I discovered that having the legs this far apart allowed the lid a noticeable deflection, so I had to add additional support underneath.