 We recommend using dado joints for
building flats. This allows for a nice "fitted" frame that is easy to use, easy to fit together with
other flats, easy to transport and easy to store. Another advantage is that you can use your dado cuts to help square
up the frame. Finally, dado cuts allow you to construct a frame that can be covered on both sides. We use double-sided
flats in a number of our productions. For instance you can mount the flats on a low boat truck or (if you're lucky
enough to have one) a revolving stage and simplify set changes.
 However, there is a work-around if you don't have a table saw
equipped with a dado blade (or a router table -- which is an alternative). Remember the scrap pieces of plywood veneer
we mentioned in our bill of materials? Use these to make "gussets". These bracing pieces can be rectangular,
but we recommend using a triangular shape because you don't end up with corners just waiting to snag a passing costume.
Butt the cross-piece against the vertical piece at right angles (again, using your carpenter's square), and then glue and
screw a gusset in place to hold the two pieces together (see diagram). CAUTION -- remember to trim your 48 inch cross-pieces
to allow 45 inches to allow for the butt joint versus the fitted dado joint. Also, remember to use pilot holes
before screwing the gussets in place.
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