Key to the City

I started this by applying the full scale pattern to a piece of plywood with a light dusting of spray adhesive. I cut the shape out using a scroll saw then removed the pattern. On the router table I rounded over all the edges I could reach and got the rest with sand paper. I used epoxy putty to add the raised bits then left it to dry.

Once dry, I coated the key in a few layers of enamel spray paint. After sanding the enamel to a mirror finish I applied gold leaf to the whole exterior.

Corn Stalk Chandeliers

My main project at Chicago Shakespeare was to build 6 chandeliers that looked like they were made from corn stalks. These hung above the stage for the majority of the show, but were flown in to floor level to create the corn field that Dorothy encounters the Scarecrow in.

The main structure was comprised of PVC pipe that I shaped with a heat gun and jig. These individual spokes were fastened to a wooden hub that held them in place and provide a pick point for rigging hardware.

The husk and leaves of the stalk were created by gluing floral wire to rough fabric. This allowed each individual leaf to be bent and shaped as desired.

With the desired shape achieved, a surface treatment was needed to sell the effect. A mixture of elsatomeric, dye, and course particulate was used to give the whole construct a rough, organic texture.

Finally, the choreography called for characters to remove some of the ears of corn from their stalks. To do this, each plastic corn cob was fitted with an interior metal tube that attached to magnets fastened to the end of the stalks.