WHEN Steve Boyd, creative director of Eleven Arches, revealed what audiences can expect when Kynren returns to Bishop Auckland this summer, he promised extra layers of detail, more special effects and larger cast numbers.

But he was not just referring to audio and lighting improvements, many of the added details to which he implies will be provided by the skilled craftspeople responsible for Kynren’s spectacular costumes and props.

Last year, the production received rave reviews, with tens of thousands of people witnessing the open-air night spectacle. Local volunteer of all ages learned everything from sword fighting and dancing, to horse riding and diving to bring 2,000 years of British history to life.

And behind the scenes, hundreds more volunteers happily gave up their free time to ensure the actors and actresses looked the part.

With the second season set to begin on Saturday, July 1, preparation is well underway and the arena site, in Toronto near Bishop Auckland, is a hive of activity.

Costumer supervisor Debra Willison and her team of volunteer sewers created 2,367 costumes last year and are now making a further 300 outfits to accommodate the extra characters.

Every week, volunteers attend a workshop where the fabric pieces are cut out and sewn. Many sewers also take big bundles of fabric home to work on during the week.

Ms Willison said: “It’s not just a case of making the costumes. We also repair them, adjust them, add extra buttons and more.

“Different people play the roles on different nights so we need to be able to adjust them to fit different sizes.

“They also need to be practical and suitable for whatever task the actor is doing. This could be sword fighting or horse riding.”

Arguably the most spectacular new costume is that of Boudicca, the Celtic queen who led an uprising against the Romans. The costume was designed and created by Rebecca Rawlinson, a North-East costume maker who specialises in intricate costumes for the Concours d’Elegance class at horse shows.

Miss Rawlinson carried out extensive historical research before making Boudicca’s gown and the Kynren team were overjoyed with the finished piece.

Over in the props shed, meanwhile, volunteers are also busy making hundreds of shields and swords for the Roman and Viking armies. The team are experts at turning everyday items such as shower rails into authentic looking weaponry, and are sticklers for detail.

Mark Rossi, who was head of art at St John’s School and Sixth College in Bishop Auckland for 40 years, is captain of painting and is looking forward to the live shows returning.

“Last year, it just didn’t seem real until 8,000 people turned out on the opening night,” he said.

“It has brought the community together and I’m so proud to be a part of it.”

Kynren runs from July to September. For tickets, visit elevenarches.org