I hate coming here and finding nothing new to talk about sooooo...
I'm working on new flats for our playhouse. I was wondering what how many community theaters still use canvas, how many are now using luan, or what other materials they might be using. We are curently switching to Laun from canvas. I have used it in the past and am very happy with it. Luan adds stability, a smooth painting surface, a place to "hang" stuff, and a LOT of flexiblity on modifing a flat to special use (special doors/windows/nooks etc)and then being able to easily restore the flat to our stock standards. Any thoughts out there. Any new ideas?

Good point on the ease of connection with the "boxy" flat. Currently, I am resurfacing striped down canvas flats made with 1x4's that have the wide side against the luan. In the past, I have made new luan flats with 2x2's. They give the some of the stability you are looking for, while still providing an excellent anchor point!.. Gee isn’t it nice to have something to talk about. lol

Don't mean to sound like a bleeding heart, but does everyone know that luan is a rain forest wood? At least, that's what I was told by this bleeding heart I worked with once.

We've used luan flats for several years. They just plain last longer. The last ones I built were about three years ago and are still going strong. We use them in just about every show. If you're careful in how you store them, like in a roomy flat rack, they should last a few years more. As for the joint left at the top, ours are 4x10 and I use either a strip of masking tape and then a heavy coat of primer or a strip of muslin and secure it with wheat paste. If you're recycling the flats for each show, the amount of paint will cover up the joint quite nicely. Also, a nice texturing job such as rag rolling or spattering can hide an otherwise obvious joint as well.