I came to Los Angeles from New York City many years ago with the hope of furthering my acting career. Like so many who do, I needed to earn a living while pursing my dream. Fortunately, I had taken an interest in set design and construction when earning my BA in theatre, and was able to find work building sets for television.
“Flats” are the building blocks of all Hollywood sets. A “Hollywood Flat” is today, the standard flat construction used on all professional film, television, and theatre sets.
A Hollywood Flat consists of 2 “Rails,” which are the top and bottom pieces, 2 “Stiles,” which are the longer, vertical sides, and 3 “Toggles,” spaced every 2’ inside the frame. They add rigidity to the flat. A “skin” of Luan is placed over the flat frame once it’s assembled. Then it’s painted, or wall papered, to represent a solid wall, just like in your home.
I’m going to explain how to make a Hollywood Flat.
Before you begin to make your flat, you will need the following tools and supply:
- Chop saw, or circular saw
- Pneumatic, or electric nail gun (staple gun)
- Screw gun (including a counter sink drill bit)
- Router (with a flush trim bit)
- Sander
- Measuring tape
- Pencil
- Wood glue
- Wood putty
- A box of 1 3/4” staples
- A box of 1 3/4” wood screws
OK. Here we go.
Step 1.
Make a “Cut List.” A Cut List tells you exactly how much lumber you will need.
For this example, your Cut List will include the following:
- 5 sticks, 8’ lengths of 1” x 3” pine
- 1, 8’ x 4’ sheet of Luan, 1/4” thickness
Cut the 1” x 3” into
- 2, 7’ 10 1/2” lengths (Stiles)
- 2, 4’ lengths (Rails) Note: You won’t get 2 4’ lengths from 1 stick, due to the thickness of the saw blade.
- 3, 3’ 10 1/2” lengths (Toggles)
Tip: Always give your 1” x 3” pine a fresh cut on each end. The factory cut is not always square, and you will need your ends to be square. (you’ve got 3/4” on both ends to play with) Always measure twice, cut once!
Step 2.
Cut all your lengths using your Cut List, and mark them using a pencil so you will know what each piece is without having to measure again.
Step 3.
Assemble your pieces on a clean table, or the floor if need be. Start with just the outer frame, your Rails and Stiles. You’ll place your Toggles later.
Step 4.
Add a thin strip of wood glue to the end of your Stile where it meets the Rail. Join the Stile to the Rail, squaring it up by feeling with your fingers. Put 2 staples (1 3/4” staples) into the Stile, through the Rail at the bottom, then top. (you will put a single screw between these staples later).
Repeat this for each corner.
Step 5.
You will place your Toggles every 2’ center along the Stiles. Mark with a pencil, measuring from one end, at 2’, 4’, and 6’ on each Stile. One at a time, add a thin strip of wood glue to each end of a Toggle, place it into position, then staple in place just like you did with the outer frame.
Step 6.
You are going to put a single 1 3/4” wood screw in each place where you have stapled. The screw goes between the staple marks. Make sure to pre-drill each screw hole first using a narrow bit with a counter sink (the counter sink makes a shallow recess for the screw head to rest). If you don’t pre-drill, you will split your wood, ruining your hard work.
Step 7.
Add a thin strip of wood glue to the top of your frame, all the way around, including the Toggles. Next, carefully place your Luan sheet onto the frame, starting in one corner, and square it to the short edge (Rail) first. You may need someone to help you steady the Luan as you place it. Once in place, staple down through the Luan into your frame. Again, start in one corner, then follow the short edge (Rail), placing staples every foot as you square your Luan to the frame. Move up the Stile, stapling, until you have secured the Luan to the frame. Staple the Toggles last.
Tip: Mark the Luan over center of your Toggles, drawing a line. This is your guide when you staple into the Toggles.
Step 8.
It is best to include this step, though you have finished building your Hollywood Flat. Using a router with a flush trim bit, rout your edges. Most sheets of Luan are not exactly 8’ x 4’, leaving as much as an 1/8” overhang. The router will remove this excess where it exists, leaving your flat square. Next, sand everywhere there are rough patches, especially where you have stapled and screwed. Finally, using wood putty, fill in all holes and divots visible on the facing side of your Luan. Let dry, then sand. This will make your flat smooth, and easier to paint.
Congratulations. You’ve made your first Hollywood Flat.