1. Explain to students the purpose of a Hollywood flat (a fake wall in the theatre or on a TV/movie set). Use the digital resource to show examples of the flat and pictures of the blueprint of a flat. See pages 8, 9 and 11 of the digital resource tool.
2. Explain the different parts of a flat:
See page 7 (on the digital resource tool) to see these parts labeled.
3. Explain to students that they are going to build a 4’ X 8’ flat frame and then glue it to a sheet of luan (thin plywood).
4. Assist students in arriving at the appropriate measurements for each of the following:
Stile (2 pieces at 7’10 ½”)
Rail (2 pieces at 4’)
Toggles (3 pieces at 3’ 10 ½”)
5. Supervise groups as they get their wood measured and cut it at the chop/ miter saw using safety goggles.
6. Assist students in laying out their wood in the proper format, making sure that the stiles are nestled under/over.
7. Starting at ONE corner, have students line up the TOP rail with the LEFT stile. Have students use their predrill to make two small holes from the top of the rail into the stile. Have them repeat these predrills on each of the four corners. Each time they get ready to predrill they should have their carpenter square lined up on the outside of the flat to ensure that it is a 90-degree angle. The predrills should hit in the middle of the 1 X 4.
8. Students should first place a small amount of wood glue in between the stiles and rails at each corner. Then have students sink 2 X drywall screws in each of the corners of the flat frame.
9. Once the outer frame is complete, measure from the bottom and make marks with a pencil at 2’ & 4’ & 6’ on either stile. These marks are where the toggles will be placed.
10. Have students insert all 3 toggles in between the markings of 2’ and 4’ and 6’.
11. Have students use their predrill to drill 2 X holes on each side of the flat frame for each of the toggles.
12. Students should first place a small amount of wood glue in between the stiles and toggles at each joint. Then have students sink 2 X drywall screws in each of the joints where the toggles meet the stile.
13. Next, students will line the entire frame of the flat with wood glue.
14. Using TWO students, they will hover the 4X8 luan over the frame of the flat and gently lower it directly onto the frame. Students will start securing the luan to the frame with the drywall screw in ONE corner and work their way down to the next corner paying special attention to keeping the frame lined up with the edge of the flat.
15. Once all 4 sides of the frame have been attached to the luan, go back and use a chalk line to snap a mark on all 3 toggles (across the flat from ONE stile to another ONE). Students should adhere about 3 screws to each toggle from the front of the luan.