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Movie & TV sets are mainly made of light weight modular units we call flats. The standard flat has a 1x3 frame with a luan or other thin light weight material skin. Flats are used as walls with openings, doors and windows. The piece above the openings, windows and doors is called the header. The piece under a window is called the plug. Understanding how to calculate rough openings is a prime skill requiring critical thinking. It is a necessary tool to be able to build sets efficiently. As an IATSE 873 carpenter you must be well versed with the average style of set construction consisting of walls with openings of all sizes made up of flats. You must be able to use the flat outside of traditional applications and apply them to unique situations. When talking about sizes of flats, doors and windows the width is the first number mentioned. 4′ x 10′ flat is 4′ wide and 10′ high 3′ x 6′-8″ door is 3′ wide and 6′-8″ high Standard Flat Construction On a standard flat the skin is the full measurement. The frame is the same dimensions as the skin. 4′ x 10′ flat has a 4′ x 10′ skin covering a 1″x3″ frame with outside dimensions of 4′ x 10′ The frame consists of top and bottom plates capturing side stiles and intermediary toggles. Toggles are the length of the top and bottom plates less the thickness of the stiles. Centered every 2′ along the length of the stiles; captured by the stiles and plates. Toggles form the middle supports to keep the frame straight and the skin flat. The plates and toggles are at right angles to the grain of the skin. This prevents dishing or shallowing of the finished surface. The skin ply has square corners and straight sides which you use to align the frame as it is glued and stapled, to the frame. |