Clockwork: Building Cogs.

Last week we began designing cogs to be used in the set for Clockwork. Initially I decided that the quickest way to make up a number of them to work with would be to spend a bit of time designing one really accurate cog, and then use it as a template to mass produce more.

I therefore looked for a circular object large enough and drew around it on a thick piece of plywood. As we had never made cogs before we considered what would be the best way to get an accurate design drawn up. We had our circle drawn on the wood and next we had to consider how we would make the teeth. All had to be the same size, and also the gaps between the teeth had to allow the same shape into them, as a cog would work.

The way I decided to design them was to measure the circumference of the circle and then divide it up into a number that was large enough to fit the right number of teeth all the way around the circle. We also left a gap either side of the teeth so that the teeth of another cog would fit in smoothly. Basically we measured five centimetres for each tooth of the cog and left a centimetre gap either side of the teeth.

Once we had marked up the measurements for the teeth I drew a line across the circle to the mark opposite. This divided up the circle so that we could draw out the teeth accurately, as is shown above. At this point we cut out the circle of the gear, planning to cut the individual teeth out after and with more ease.

With the cog cut down to its circle we began to work with a jigsaw to cut out the individual teeth accurately and precisely. Once this was done we had our first cog shape and would be able to use it to stencil more

and quickly make more.

Above you can see the first completed cog, as we were unsure whether they would be stationary or move whist hung we decided to cut out the circle in the middle to give us the option. As the circle hadn't been drawn but had formed as a result of the lines we had drawn across the surface this gave us the impression we had been more or less spot on with our accuracy.

Once the circle was cut out the middle of our experimental cog we began to increase in the rate of our work. Although at first we had taken our time to create an accurate shape, this had been completely necessary and we could now not only use this cog to quickly make more, but also put into practise what we had learnt to make cogs of varying sizes. Which we avoided at first, preffering to get one right before branching out and over complicating things.

With each cog completed we painted them with a black base coat. As they became incredibly easy to make we bashed out about six that day including two that were joined together permanently, as is shown below.

Originally these two cogs had simply been drawn very close together to fit as many on the wood as possible. However, we decided whilst cutting them out leave them attached together. Rather than struggle to hang them perfectly next to each other we could keep them left attached and give the same appearance. Even here on the ground they look like they have just been placed next to each other.

As we had spent all day in the workshop I took the cogs to finish off at home with a dry brushing technique I had developed during Sweeney Todd. This was very useful as I could quickly paint up a large number of pieces to a standard high enough to be viewed hanging from the rig in the theatre. Here I experimented with a look that made the cogs looked wooden but flickered like brass. One PT student even asked me what they were made of, which I was pleased to hear as it meant we would be able to convincingly make them look like they had been constructed of a different material to wood. For this batch I tried out a number of variants that all gave an oaky, yet brass look to them. I think for the next few I will try something colder, more silvery and steel-like, but for the mean time I was happy with what we had achieved and learnt, especially from experimenting with new techniques we had to develop ourselves as we went along.

Clockwork: Buildig the Sleigh

Last week we completed building a sleigh for the PT group to start rehearsing with. Initially Kasia had wanted a sleigh that was large enough to fit three people in and sturdy enough to be worked with by the physical theatre students.

Originally sketch for the sleigh, originally I had considered mounting the structure on steel deck.

Originally I had considered building some kind of sleigh on top of a piece of steel deck I had put wheels on for use in rehearsals. However, Kasia decided this wouldn't be easy to work with, due to the weigh and shape. As she didn't mind the performer's legs being on show, I suggested that we build a sleigh frame instead, which could be held up by the performers.

The final design for the sleigh, focusing on the frame instead of the whole structure.



With the design in place we started construction of the sleigh. As we were only constructing its frame I decided to use quite a thick wood. This would give the structure the strength it needed to be used in rehearsals without being too heavy and awkward.

Primarily the sleigh would be constructed of three main pieces (the two sides and the middle frame section). I therefore divided up the wood and drew out the middle frame piece first. As this was the simplest part to draw out I did it first so one of us could get on with cutting out the frame whilst I drew up the two side sections of the sleigh, which would take longer to design.

Once we had one of the sleigh sides cut out we checked it next to the bottom section of the sliegh to see of it looked in proportion and line up perfectly. I then sanded it down ready to draw out the other side on the remaining wood.

Once I had drawn out a design that fitted both side sections of the sleigh on the same piece of wood I  began cutting it out. By cutting one piece out and using it to stencil the other side we maintained an exact size of the sleigh design. Once we had both sides drawn out we could work separately on the two pieces.

With the two sections separated we began to cut out the outline of the sleigh to give it its light-weight frame. As well as the middle section we would be putting in a number of supports to hold the whole structure together.

Completed side frame of the sleigh.

The frame work assembled.

 Once the main pieces were completed we sanded them down and began gluing and screwing them together. In order to get strong bonds between the pieces we glued them and braced them together with clamps while they dried, before screwing them together for added support.



Once the pieces had dried we added in a number of supports hidden on the inside of the frame work. This gave added support to the sleigh but didn't change the look of the sleigh or detract from its design. We also added some batons of wood that joined the two sides of the sleigh higher up. This gave more support but also made it easier to hold the sleigh up. Our final job was to paint the sleigh and get it into the rehearsal space ready for the PT lot.

Completed sleigh.