Although I don’t generally like doing repairs (there are exceptions) it’s part of the business, and sometimes interesting to find out how something is made.

One of my clients asked me to mend a hat that he uses for some of his gigs. The brim is quite thick, and its shape was disintegrating. Much to our surprise there were lots of little chunks of wood inside! On the intact side the bits were glued together into a set shape, but elsewhere they were broken up and higgledy-piggledy. Today I poked around a bit more and ended up taking them all out. I’ll probably replace them with shaped foam.

The hat is from the Calcutta Sola Hat Agency, which was enough of a lead to work out on Google that this is a sholapith helmet, and the bits inside are actually pith! It’s the inside spongy core of a water plant which can be pressed and shaped into works of art. I hadn’t ever looked into why pith helmets had that name. It looks as if the hat makers pressed the pith into a newspaper-lined hat mold, and then sealed it off with a few more layers of paper, before covering it with cloth.

The custom softie I was making last week was “Officer Dan”, the face of a new board game called Highway Patrol. He will be part of the game promotion when its inventors travel to the International Toy Trade Show in New York next week.

I’ll post a few more making photo’s in my photoset at Flickr in the next day or two.

The windmill prop I mentioned previously was made for the National Museum of Australia‘s July school holiday program Little BIG Things. It ran in conjunction with the museum’s new Landmarks exhibition, which explores a broad history of Australia through stories of places and their peoples.. The kids visiting the Discovery Centre drop-in activity area could make small sculptures of a big thing from where they came from, and then write a story about it to place on the blades of the windmill.

Against the huge windows in the foyer of the museum the windmill looks quite small despite being 3 metres tall. At home when I did a trial assembly of the windmill outside my studio window, it looked enormous! There are some more photos of the windmill in my Flickr photoset.

I’m working on a windmill prop at the moment. I made the base structure a month or so ago, but am now back to making the blades. The windmill itself is very simple, but it’s size – it will stand 3 metres high – makes it logistically tricky to work on in my studio. It’s coming together nicely, though, and I’m enjoying it.

I made this giant garden fork prop for  The Fool Factory recently. There are some making photos in my portfolio at Flickr. Before I handed it over we had fun posing with it like the farmer couple in Grant Wood’s American Gothic painting and various other silly things. It definitely invites comic scenarios.

Earlier this year I made the set and props for Flotsam and Jetsam, a production for children which tells stories about living on Australian lighthouse islands in the past. The script was written by Greg Lissaman, from recollections gathered by Chrissie Shaw, the actor. Catherine Roach is the director.

The set is an island, panels painted in a pointalist style, which can concertina into different shapes and be dismantle for touring. The lighthouse is modelled on the historic lighthouse at Cape Otway in Victoria, and Tasman Island in Tasmania was among other sources of stories and images, such as the flying fox access to the island. There were numerous props – seaweed, wooden chests, a porcelain doll, an albatross, and a sea buoy. There are more photos of these in my  Flotsam and Jetsam photoset.

Touring dates and booking details for Flotsam and Jetsam are listed at Chrissie’s site. On 19 – 21 August it has a short season at the Maritime Museum in Sydney, and then it will tour coastal community venues in NSW. Chrissie also performs The Keeper, an adult play also based on lighthouse stories.

This suggestion of a seagull skeleton is a prop for a new play I’m working on, but I rather like it as an object for itself. It’s given me some ideas for making some stranger ones when I get some time later.

By coincidence, today I happened across Chris Jordan’s photographic collection Midway: Message form the Gyre, a photographic documentation how albatross chicks on Midway Atoll ban in the middle of the Pacific Ocean often die because they end up being fed heaps of plastic junk. It’s shocking – only look if you are feeling strong.

I have some catching up to do on posting about my work projects.

First up is the cross-section wheat seed that I made for CSIRO Plant Industry, for their annual display at Floriade in September. In other years I’ve made a caterpillar and cross-section flower for them.  The wheat seed is carved out of polystyrene, and surfaced with a mixture of materials: fabric, paper mache, paint and latex. There is a photoset of the process.

I was pleased when I realized I could use a strange stretchy and very synthetic fabric for instant and variable cell textures.  I had used this fabric for skin texture on a goanna puppet in a TV pilot years ago.  At the time the pilot program was taken to a childrens’ program market in Cannes, and there was hopeful anticipation of it being sold to China. Someone with dollars in their eyes advised buying up extra fabric against the day when we went into full goanna and other animal puppet production, but there I was ten years later cutting into it for the first time!

The unlikeliest thing about the wheat seed was how cute it was. Everyone who picked it up cradled it like a baby, and admired its cute little tuft of bristles!

Here are some of the puppets and props; check my Flickr portfolio set for others.

The meercat and the meercat hat:

Yiying Lu in the meercat hat!

I got rather fond of the hat…

The pirate captain (finger puppet):

The rat (rod puppet):

Kevin, the polar bear (worn on shoulders):

Hans and Donaldine, or the other way around… (glove puppets):

The shark (worn on shoulders):

The amoebas (glove puppets):

The eggbeater time machine! Love this great design idea!

Two rockets:

The multiple eyes of Veruna, the water goddess. In motion.

This is the big dead manta ray prop that I made for the Street Theatre’s production of Jacques Brel is alive and well and living in Paris.  Sadly Desirée – my name for her  – was cut from the final production, but I loved making her.  Manta rays are such awesome creatures!

Because she had a wingspan of over 2 metres, I decided chalk on the floor was a good way to start drawing up a pattern. I also bought myself a little plastic model of a manta to refer to, which turned out to be useful.

From this I traced a pattern onto butcher’s paper and from there onto sheets of polystyrene which were then built up and glued into a block.

I also decided to insert a strip of thin plywood into the underside right across the width of the wingspan, so that the wings would be protected from breaking, especially at the tips. I also did that with the fins that I added.

Then much shaping with a really sharp knife, a narrow power belt  sander, and sandpaper. I decided to keep the surface a bit rough, which often makes it easier for an audience to read.

When I use polystyrene that will just have a painted finish I skin it with muslin first. Here you can just see some of the muslin draped over the spray adhesive can on the right.

I usually add a little bit of latex to the first coat of paint to help make everything stick to the styrene.

Then it’s on to colouring; for the final shading I used spray paint so that the colours merged softly. It was tricky to seat in the eyes (painted and glossed wooden door knobs) and get the shape of the upper eyelid right.

There are a few more in-between photos in my photoset at Flickr.