How to Build Light Bars for Stage Props

Stage lighting hung from a batten illuminates a stage curtain.

Theatrical lighting instruments can be hung from just about anything that's sturdy and stable. In the concert industry, instruments (or fixtures) are hung from trusses, and in theater, they are hung from pipes called battens. Many battens are "flown"--suspended on a rope-and-pulley system known as a "fly rig." If the batten has a power or control (DMX) cabling system associated with it, the batten is called an "electric."

Smaller theaters often do not have these elaborate systems and the battens are attached to the ceiling, side wall or balcony rail. Making a simple batten from standard 2-inch galvanized plumbing pipe is an easy task.

Things You'll Need

• 2-inch galvanized plumbing pipe threaded on both ends (standard length is 21 feet, but it can be cut to the desired length)
• Two10-inch long 2-inch galvanized pipe nipples threaded on both ends
• Two 2-inch galvanized 90-degree pipe elbows
• Two 2-inch floor flanges (base plates)
• Eight 1/2-inch x 3-inch hex head lag screws
• Two pipe wrenches
• Two electric drills with 1/4-inch bit
• Two 1/2 hex head ratchet wrenches
• Two pencils or markers
• Two ladders (or lifts) tall enough to safely reach your mounting positions

Instructions

Assembling the Light Bar

1. Buy the galvanized pipe and fittings from your local hardware or plumbing supply store. The store personnel will cut the pipe to the desired length and thread the ends for you if necessary. Assemble your tools.

2. Lay the pipe and fittings on the floor of your work area. Screw one end of each nipple into a flange. Screw the other end of each into an elbow. Tighten with a couple of pipe wrenches; it doesn't have to be real firm. These are your bracket assemblies.

3. Screw one assembly onto each end of the long pipe. Firm them down with the pipe wrenches, making sure that each assembly is in line with the other. What you should have is one very fat "U" shape. Stand the assembly on the floor using the flanges as feet and adjust the tightness of each elbow until the assembly stands evenly flat on both flanges.

Hanging the Light Bar

1. Climb a ladder with a pencil in your pocket and one end of the light bar assembly in one hand. Have a helper do the same at the other end of the assembly. Hold the flange to the mounting position and mark the screw holes of the flanges on the mounting face.

   Note: Your light bar must be mounted into a solid surface such as a glue-lam beam.

2. Descend the ladder and lay the assembly on the floor. Climb the ladders again and drill 1/4-by-3-inch pilot holes into the mounting surface at the pencil marks.

3. Climb back down the ladders and retain the light bar assembly along with four lag screws and your ratchet. Head back up and place the flange against the mounting surface. Position your shoulder against the bar to hold it to the surface.

4. Place a lag screw in the first flange hole and ratchet it down. Ratchet a lag screw into each of the other holes. Firm them up and you're done. Now you're ready to hang lighting instruments from the batten.

Tips & Warnings

• It's not necessary, but you may wish to paint your batten a nice flat black before hanging. To do so will require you to first strip the oils from the pipe with a solvent. Keep in mind that paint will quickly flake off the pipe as the hanging clamps from the lighting fixtures are tightened onto the batten.

• Be sure your mounting base is made of thick, heavy-duty wood and that your lag screws have a good bite. The batten will be supporting a lot of weight, and you don't want it crashing down.

• Use great care when climbing ladders--especially when carrying a heavy load in one hand.

References

• Illustrations of Pipe Fittings
• Batten Diagram
• Photo of Light Bar