The set for Henry IV was almost entirely designed in hand-hewn beams, allowing the medieval settings to vary from barns to caverns; from castles to battlefields. We were hired to cast the Beams. They had to look like wood, but could not be wood - as there were strict fire codes in place.

We just happened to have an old cow barn in the back yard,and were able to cast beam samples for the Designers. We used various wood stains to make samples for them to choose from.