Stage crew may have been a very demanding job during shows builds and during productions, but there were also long periods of time were little to now work was required. During the winter and summer months, no sets are requested by the program, so stage crew members go into the offseason, grinding through resources kept from the previous show.
The amount of lumber our program purchases for shows is astounding, and even though we reuse most of our supplies, the remainder of the stockpile is left with an uncertain fate. The climate control in our antiquated theater is effectively nonexistent. This means that most wood products will severely warp due to temperature changes, if they are stored backstage for long periods of time. Why waste a forest when you can give it to a group of teenagers to use?
I realized the full potential of this surplus during my senior year, and I ended up using it for several projects for school and personal use.
I was enrolled in AP Physics C my senior year, which had a project-based lab component. Each academic quarter had a new build, ranging from bridges to a radio. Using my construction savvy and excess materials, I was able to craft some memorable products.
The bridge
Saw work on a small scale is incredibly difficult, and the bridge project only reinforced this point. Our first lab was the iconic bridge breaking scenario, where our groups needed to achieve the highest payload to bridge weight ratio as possible. This required me to cut a span with several jigsaw cutters, while ensuring that the powerful tool did not shred my thin span to splinters. Thankfully, I had been working with the jigsaw for several years, so I was able to safely cut a span that satisfied the weight limit.
The Guitar:
This one was my favorite project
Our second lab assignment required the class to form bands with fully-functional instruments. I have played the guitar for over a decade, so I felt that it would be fun for me to make my own guitar.
I immediately raided the stage crew surplus and put together the basic structure using 1x4s and lauan plywood. I sanded the neck from a regular 2×4 and then used wood stain to give the instrument a traditional livery.
This strings were incredibly difficult to mount and properly tune, but I eventually had a working instrument in the workshop. It may not stay in tune for extended periods of time, but there is no doubt that it can still play lovely music.
It is wonderful that our wood, which was slated for the dumpster, could be repurposed into our side projects. It made stage crew into a year-long hobby.