At
the beginning:
Our brief was to get the car in the pod by 12.30am on the night of the
shoot. That would give the film crew four hours 'night' shoot, till
the sun started to poke it's head up.
The Recce
It was a warm night, and we needed lots of answers.
The Eye shuts at 9pm, and the last customer is off by 9.30pm. That would
give us a three hour window to get the car in. Easy if you're driving
the car in off the road, right?
Except in this case (as you'll know if you've been there) you can't
drive a car straight from the road into the pod; the 'bottom' pod is
at deck height, a good 1.5 metres above ground level. Complicating matters
more, there is a zigzagging queuing slope with glass panels lining it,
running up to the ticket booth and deck, blocking our way through. Complicating
things further, there are also vertical structural beams, reducing our
angle of entry.
So we needed to have the glass panels removed from the walkway, to create
space for the thirty foot long on / off ramp, that would make it possible
for the car to drive up and onto the deck. Would BA be happy taking
those glass panels off?
On top of that, we had a major issue; the benches in the middle of the
pod were not removable. They housed electronics and equipment that were
integral to the pod. Added to that, the car was too wide to fit through
the pod doorway at deck level (because the doorway curves outwards vertically
when you look from the front). It would only fit through if the doors
were taken off, and the car was driven through 700mm above deck height.
Other than close the wing mirrors on the car in, we had no options modifying
the car. The only way forward was to create a raised deck inside the
pod, just over the height of the bench seating in the centre. This also
meant we would need to remove the doors to the pod; the car would squeeze
in if the wing mirrors were closed. Would BA be happy with the doors
being removed?
Also, the implications of having a false deck inside the pod, meant,
as the car drove out of the pod (for the ad), the existing deck it drives
onto would need to be raised to the same height; all fifty feet of it.
The other issue was the position of the pod. We needed the pod to stop
within fifty millimetres of our mark, to allow the car to drive out
between the vertical columns. The problem, is that the 'stop' button
in the control room on the Eye, once pressed, has a built-in soft-stop,
to protect the motor and mechanics of such a large unit. The size of
the wheel also meant that there was a certain amount of play; stretch
if you like that made it impossible to stop the pod in the same place
every time (of course the wheel is in continuous motion during the day,
so it had never actually needed to stop on a specific point - until
we came along... Nevertheless, ten minutes of shimmying backwards and
forwards meant we would be able to stop it within fifty millimetres
of our mark.
Answers
Thankfully BA were happy to help us with the removal of the glass panels,
and the doors to the pod. The glass panels would take between an hour
and an hour and a half to take out, and the doors would take an hour
and a half. This reduced our installation timeframe to one and a half
hours. Within reason, we would be able to unload and start a few bits
and pieces. But in general, because of H&S procedures, it would
be necessary to wait for the glass and doors to be fully removed.
The Upshot
So we had a one and a half hour timeframe to install a thirty foot aluminium-clad
ramp, fifty feet of raised, aluminium-clad decking, a raised, aluminium-clad
deck inside the pod, re-rig the pod doors to hang wider than normal,
two custom built lights (that fit in the pod ceiling without marking
it) and get the A2 car inside without making a dent or a scratch anywhere...
Two and a half weeks to prepare, fabricate, test and write a comprehensive
Risk Assessment.
Which we did.
The Installation
Another warm, balmy night. While the glass panels and pod doors were
being removed, we were unloading everything into designated spaces.
Every team member had a minute-by-minute schedule for the one and a
half hour installation. It was a case of whoever was up on their schedule,
helping the person most behind on theirs. As with a team marathon, you’re
only as quick as your slowest member, and this was the linchpin of the
success within timeframe.
Once the glass panels and doors were off, we started. The team split
into two; one ramp team and one pod team. The ramp team had the relatively
simple job of building the steel ramp in line with the pod. The pod
team had to squeeze the car into the pod (with 15mm clearance) and up
onto specially built ramps that would support the car over the bench
seating. Unfortunately because the door height was too low to allow
the car in at the total raised height, we had to then jack the car up
a further 300mm by hand on each of its four extra long jacks. Once jacked,
the ramps could be removed, and replaced by the higher, aluminium-clad
decking runners. 300mm wide, and built to take the extra weight of the
car. The car was then slowly lowered with the jacks onto that deck.
The car in position meant we could install the rest of the deck into
the pod. This was a lighter weight, aluminium clad decking that could
take the weight of people, but didn’t need to take the extra weight
of the car.
While the decking was going in, the pod doors were being fitted to look
as though they had been slid open.
As the ramp and pod team started to finish their jobs, they began moving
the raised deck into the main thoroughfare. Fifty feet long in 8’x4’
sections. That done, we were done. Fini.
A Cup of Coffee
We hit the finish post ten minutes early. Not a scratch on the car or
pod, and ready for a night shoot.
Eight
tonnes of steel, one aluminium car, one large rotating wheel, a precision
driver and a great team of experienced professionals.