Produced the design drawing for the slipring system. Ordered more welding gas. Tried to contact Adrian regarding paint codes for the awning, lift interior and whether he wanted the wardrobe to go circle patterns.
Revised workplan for tonight is to grind down the external welds on the two fully welded door frames. Drill wardrobe hinge holes. Drill plank securing holes. Cut the awning support frame and final few short door frame segments.
The brass sheet has arrived. It looks thinner than expected, but I put in a posting to crew-talk to determine whether it will actually be suitable. The brass has a resistance of 2.75x10-2ohms/m, a birdie lamp a resistance of 2.4ohms and the EL Wire a resistance of 24ohms. The voltage drop on the brass if therefore 12*(0.0275/(2.4+0.0275)) = 0.136 and 12*(0.0275/(24+0.0275)) = 0.0137 respectively. This gives a power dissipation on the brass of 0.1362/0.0275 = 0.67W and 0.01372/0.0275 = 0.68x10-2. This is also a worst case scenario based on a full metre of brass wheras in actuality it will be nearer .3m of brass. It is anticipated that the 6W car lamps intended for use on the lift doors will be nearer the 500mA current draw of the EL wire.
Made various notes over the weekend regarding the design work still to be done. Need to work out what construction work needs to be done prior to Saturday.
Still mulling over slip-ring concepts. Although the materials need to be purchased this week, all of the construction should be done the following week to ensure that the metalwork gets done this week.
Ordered material to build the slip rings as well as additional M5 countersunk machine screws.
Cut the final few pieces to make the door frames. Cleaned up the pieces for the awning frame and drilled the M10 mounting holes. Drilled all of the hinge holes whilst I was at it. Welded up the awning frame, one of the black frames and half of another before the gas on the welder ran out. Will need to take the grinder in to grind down the exterior welds tomorrow.
Placed the Flints order. Have obtains 5l of Mylands fire retardent paint rather than the Bolloms. Also added the Flambar for Adrian. Have decided not to care about the 16th ball transfer unit. Didn't add M5 screws, but am concerned that there may not be enough in my mixed box to cover all 7 frames. If necessary we'll have to do a run to Flints to pick up a box. Decided that we can probably raid Dramsoc for woodstain, otherwise it could be picked up from B&Q at some point.
Did a quick tally of the budget. We've so far spent £731.25, still left to purchase are the U Section Steel for the lift, 12mm doweling for the lift and coloured paint. With a bit of luck we should squeeze in just below the £800 mark.
Cut the short lengths. Drilled and countersunk the screwholes. Countersunk the
Worked through the cutting diagrams for the 4mm ply. Will have to reduce the awning depth to 300mm if we are going to use the given ply. This is useful in many respects because getting the 600mm sections out of the remaining steel was going to be a tight call with no room for error.
Sketched out a simple box design and how to get the plank, awning faces and box out of the remaining 12mm ply. Need to redraw the
Trying to work out if we can do 12v slip rings rather than a coiled cable since both all of the lamp types that we are after will be low voltage. Even suggested using scalextric track to provide a circular strip. For safety all of the metalwork should have earthing.
Further cutting of the long lengths. Drilled all of the screwholes. Brought in my box of machine screws which contains some M5 countersunk screws. Tested the door frame edge against a vertical using the hinges. It's stiff, but that's probably for the best. We can always loosen the hinge loops and add oil to make it easier if that is deemed preferable.
Started cutting the long lengths required for the
Had a slight dither yesterday when I realised that the interior facings which are supposed to be attached to the doors wouldn't be able to pass through into the box because the box is significantly smaller due to the verticals, and floor and top frames. The door however are hinged such that they could be opened backstage without being seen so that the interiors can be flipped over.
Mailed Steve to ask him put in the Flints order. Added Adrians flambar to the order.
Early start to get the next four bits of steel cut for the base. Marked, drilled and countersunk. Welded them together just after lunch. Fitted up and drilled the M10 holes for the verticals and assembled the entire box structure.
Set Luke to work cutting the turntable and base from a sheet of 12mm Ply. Turntable was cut with a router and circular jig. Spotted at the last minture that my drawing were erroneous and that the diameter of the turntable needed to be 880mm rather than 892mm. Holes for the ball transfer units and trenches for cabling were done.
Fitted the ball transfer units to the turntable and the lazy susan bearing with some hardboard standing in for the packing. Tested the assembled box on with about 140kg of weight which is our nearest approximation to two people. The box seemed to move reasonably freely even under the load. The box also appearead to be fairly strudy, once the doors are hung it will be possible to determine whether additional bracing is needed.
Wood order arrived. The 4mm ply is very flimsy and somewhat warped. Might have to rethink the lift door to give it extra support.
Wood ordered, should arrive Friday PM. Can't remember whether I ordered 35x19mm or 25x19mm. We'll see when it arrives, the only concern is that the M10 inserts won't fit correctly.
An earlier start than Wednesday. Proceeded to cut the 4 mitred sections for what will become the top frame. Only two required additional bench work where the blade had wandered slightly. Proceeded to weld up the frame and then drill the corners to fit the verticals. Decided on matching corners to verticals so everything has been labelled using permanent marker, will need to work out how to preserve this information when
Bandsaw arrived and is set up in the chairstore. It works a treat making very acurate cuts with minimal effort, although annoyingly getting it into College trashed the luggage rack on Kate which will require a sizeable amount of work to straighten it out again.
Wood has been ordered from Fulham Timber, total cost inc. VAT is £183.57, the £14.50 discrepancy from the original budget is delivery.
The metal cutting bandsaw was on offer, so I've ordered it, a coolant pump system, cutting fluid and a 90degree welding vice. Hopefully it should all arrive tomorrow in time for set building in the evening.
Sent out an email explaining that I'll be set building on Wednesday and Thursday for the next two weeks.
Cut and drilled a replacement vertical for the
Production meeting in Pimlico. The lift interior needs to clash with the green costume that Charity is wearing, Adrian is suggesting a smokey orange of some variety. Pompeii club also needs a colour, the costumes will be oil slick at that point, ie. mostly black but with highlights of emerald green and peacock blue. I also pointed out that we can probably blag the EL wire from Chess in order to do a name on front of the awning. I need to research some suitable cursive script to act as a template.
Will wants a cost comparisson between Flame Retardent and standard plywood so that he's got the details for next time. The flame retardent total is £131.15, WBP would have been £60.73.
Need to add Flambar to the Flints order so that the fake-fur rug that Adrian wants can be fireproofed.
Steel arrived at the Union, rebuilt the workshop in the chairstore and set to work building the first few bits of the set. Decided to tackle the verticals first since they are straight 90 degree cuts. 3 of the 4 turned out fine but the boltholes on the 4th came out wrongly. The piece of steel can be recycled into a door vertical or the pieces of the awning frame. Located the M10x25mm bolts that are needed to assemble the box.
Talked Adrian through the plans. Notes were, a lift button would be nice on the lift doors. Some form of lap-bar for the ferris wheel. Need to add flambar to the Flints order since we have to Flambar a large fake fur rug.
Screwfix order arrived. Annoyingly the righthand rising butt hinges as they label the are defined as righthand when standing behind the door opening away from you and all of my drawing to date were based on lefthand rising butt hinges. It's not problem, but everything needs to be redrawn.
A massive push to get everything modelled. Spent several hours working on both variants of the rising butt hinges for my CAD library. Modelled a lazy susan bearing so that the entire box can now be assembled.
Ordered the steel, delivery to the Union for Friday. Acton Bright Steels couldn't do the small C-section, so I'll have to source that from B&Q or somewhere like Travis Perkins. They are going to confirm that delivery on Friday afternoon after 1pm is possible. I'll need to organise timber this afternoon for delivery at the same time.
The plan therefore is to do a sizeable chunk of the cutting and drilling next week. I'll need to get the welding gear into college at some point towards the end of the month. Need to place or get to Flints to pick up the black serge, paints and extra metalwork.
| Item | Individual Cost | Quantity | Total | Supplier | Notes |
|---|---|---|---|---|---|
| 40x40x4 Bright Drawn Mild Steel | 13.47/3.4m | 20 | 269.40 | Acton Bright Steel | |
| 19x25mm Prepared Softwood | 0.53/m | 24 | 12.72 | Fulham Timber | Frame internals for stapling |
| 12mm Flame Retardent Ply | 41.95/sheet | 2 | 83.90 | Fulham Timber | |
| 4mm Flame Retardent Ply | 15.75/sheet | 3 | 47.25 | Fulham Timber | Interiors, Wardrobe Door, Lift Door |
| 1.5m Black DFR Wool Serge | 7.82/m | 8 | 62.56 | Flints | |
| Water Based Primer | 39.95/5l | 1 | 39.95 | Flints | |
| Redaluma Fireguard Black | 13.89/2.5l | 1 | 13.89 | Flints | |
| M10x25mm Set Screw | 5.12/100 | 1 | 5.12 | Flints | Frame Asssembly |
| Flambar PE6 | 7.00/l | 1 | 7.00 | Flitns | To fireproof synthetic rug |
| Righthand Rising Butt Hinge | 1.95/pair | 8 | 15.60 | Screwfix | Frame Hinges, Wardrobe Hinge |
| Lefthand Rising Butt Hinge | 1.95/pair | 1 | 1.95 | Screwfix | Wardrobe Hinge |
| 160mm Stainless Steel D Handle | 2.12/ea | 2 | 4.24 | Screwfix | Lift Handles |
| 175mm Victorian Bow Handle | 1.69/ea | 2 | 3.38 | Screwfix | Lift Handles |
| 1830x19 Chrome Round Rails | 16.59/5 | 1 | 16.59 | Screwfix | Awning Support, Wardrobe Rail |
| Twin Wheel Castors | 3.74/4 | 1 | 3.74 | Screwfix | Awning Support |
| Silver Hammer Paint | 4.67/500ml | 1 | 4.67 | Screwfix | Lift Interior |
| 3.5x12 (1/2" No.6) Screw | 1.85/200 | 1 | 1.85 | Screwfix | |
| 4.0x20 (3/4" No.8) Screw | 2.47/200 | 1 | 2.47 | Screwfix | |
| M6x30mm Countersunk Machine Screw | 1.92/100 | 1 | 1.92 | Screwfix | Hinges |
| Rustins Brown Mahogany Wood Dye | 2.99/l | 1 | 2.99 | Axminster | Wardrobe Door + Interior |
| 12x12x3mm U Section Steel | 5.00/m | 2 | 10.00 | B&Q | Lift Door, nominal 12mm int dim |
| 12mm Nylon Rod | 7.82/m | 1 | 7.82 | RS | Lift Door to fit above angle section |
| Sub-Total | 619.01 | ||||
| VAT @17.5% | 108.33 | ||||
| Total | 727.34 | ||||
Finished enough of the box to pull together a scene chagnes document up for the rest of the crew to peruse.
Further work on the 'box'. I'm still unsure how to go about doing the actual lift door across the front, but I have worked out how to do all of the interiors. Two sheets of ply cut to fit the inside of the box, although possibly smaller so that they can be manouvered out of the box. One side is varnished/stained to look like the inside of a wardrobe, the other is painted/covered to look like the inside of an elevator. Flip them around to achieve the different effects. The timber battens on the inside have M6 or M10 inserts mounted in them, and the facings are attached with thumbscrews. Disadvantage is that 6mm FR ply is £19.75 against the £3.82/sheet of the hardboard. Unsure whether 4mm ply will be strong enough, cost £15.75/sheet.
The lift door is going to have to be a concertina type affair. I'm just concerned about getting the engineering right on it so that it works smoothly. The handle end need to be flat onto the
Called Acton Bright Steels to get a price on 40x40x4 angle section. It comes in 3.4m lengths at £13.47/length. I need a total of 20 lengths, total cost £269.40, plus VAT @ 17.5%. Delivery is free.
Trying to work out how to do the interior of the lift. Rosco Mirror material is £21 for 1.5x9.15m, however I'm concerned that this could reflect the backstage area. Other options are silver flooring tiles from Screwfix at £11.91 plus VAT (£13.99inc). These would need listing as non-standard materials on the technical form for the theatre. I've not found any suitable aluminium flooring sites in order to obtain prices, B&Q probably do something suitable but only in the shop, not online.
This set me to working out the rest of the budget properly.
| Item | Individual Cost | Quantity | Total | Supplier | Notes |
|---|---|---|---|---|---|
| 40x40x4 Bright Drawn Mild Steel | 13.47/3.4m | 20 | 269.40 | Acton Bright Steel | |
| 1.5m Black DFR Wool Serge | 7.82/m | 8 | 62.56 | Flints | To cover 4 sides of the box. |
| Water Based Primer | 39.95/5l | 1 | 39.95 | Flints | |
| Redaluma Fireguard Black | 13.89/2.5l | 1 | 13.89 | Flints | |
| 19x35mm Prepared Softwood | 0.53/m | 24 | 12.72 | Fulham Timber | |
| 12mm Flame Retardent Ply | 41.95/sheet | 2 | 83.90 | Fulham Timber | |
| 3.2mm Hardboard | 3.82/sheet | 4 | 15.28 | Fulham Timber | |
| Sub-Total | 494.70 | ||||
| VAT @17.5% | 86.57 | ||||
| Total | 581.27 | ||||