Rigging a Condor Boom Lift: Weight, Safety & Strategy

Imagine lighting a scene that stretches for hundreds of yards, under the cloak of night. How do you achieve even, controlled illumination at that scale? The answer, often, is a Condor boom lift. I’m Shane Hurlbut, ASC, and in this exclusive excerpt from our Film Production Rigging course, we’re going up — way up — with a 120-foot Condor, revealing the real-world planning, rigging, and safety considerations that go into creating cinematic magic. Joining me are my trusted gaffer, Tom Sigurdsson, and key grip, Brendan Riel, to break it all down.

WHY A CONDOR? CHOOSING THE RIGHT TOOL FOR THE JOB:

For this particular night exterior, we have a challenging scenario. Our scene involves a car traveling down a road, covering approximately 150 yards. We need to light that entire stretch of road evenly and consistently. 

While there are many ways to approach night exteriors, a Condor boom lift offers several key advantages in this situation.

HEIGHT AND REACH

A 120-foot Condor allows us to get our light sources high above the surrounding trees and obstacles, creating a broad, even wash of light.

STABILITY

We’re opting for a straight-arm Condor, rather than one with a jib or knuckle. Straight arms offer superior stability, especially at significant heights and with heavier lighting payloads. Jibs, while offering more articulation, can be prone to swaying or failing under load.

CONTROL

A Condor provides precise control over the positioning of our lights, allowing us to fine-tune the angle and direction of the beam.

THE LIGHTING PLAN: EMULATING A MAXI BRUTE WITH LEDS

My go-to approach for lighting large night exteriors has often involved Maxi Brutes — powerful banks of incandescent PAR lights. They create a beautiful, directional beam that can be “wasted” off the set, creating an even wash over a long distance. However, technology has advanced, and we now have LED options that offer similar (or even superior) performance with greater flexibility and efficiency.

For this setup, we’re using four Nanlux 2400B LED fixtures. These powerful lights, combined with 30-degree reflectors, will effectively mimic the output of multiple Maxi Brutes. The narrow beam angle allows us to create a focused, long throw of light, minimizing spill and maximizing control. The idea is to “full spot” the lights and then position them so the beam just grazes the top of the set, creating an even wash of light from the base of the Condor all the way to the end of our 150-yard stretch of road.

ADDING DIMENSION: MOVING LIGHTS FOR BACKGROUND HIGHLIGHTS

To add depth, dimension, and visual interest, particularly for wide crane shots, we’ll also incorporate moving lights (often referred to as “rock and roll” lights) into our Condor rig. These remotely controllable fixtures allow us to highlight specific elements in the background, such as trees or buildings, creating a sense of scale and visual separation. We can also adjust their color temperature slightly differently from our main moonlight source, adding subtle color contrast to the scene.

THE SETUP: A DETAILED BREAKDOWN 

It’s time to break down the technical details of our Condor setup. Gaffer Tom Sigurdsson explains the mounting, power, and control systems that will bring our lighting plan to reality.

The four Nanlux 2400B fixtures will be mounted in a custom cage. This cage allows us to remove the yokes from the individual lights, reducing weight and creating a more compact unit. This cluster of lights will be positioned at the top of the Condor basket. Power will be supplied by a Santa Fe fleet battery tow plant, providing clean and reliable power for the duration of the shoot.

Crucially, we’ll use a lunchbox with data connections to allow for remote control of the lights. This means our lighting programmer, positioned hundreds of feet away, can adjust color temperature, intensity, and the movement of the moving lights without needing to be in the Condor basket itself. This is a huge advantage in terms of efficiency and safety. The use of the LED lights also bring a benefit over the older, traditional Maxi Brutes.

RIGGING AND SAFETY: THE PARAMOUNT CONCERN 

Now, let’s get into the nuts and bolts of rigging the Condor. This isn’t just about attaching lights; it’s about understanding weight distribution, capacity limits, and the engineering principles that keep everything safe and stable. Key Grip Brendan Riel breaks down the essential considerations, from weight restrictions to the rigging plan.

WEIGHT RESTRICTIONS 

Every Condor boom lift has specific weight capacity limits, both “restricted” and “unrestricted.” The “unrestricted” capacity (in this case, 500 pounds) applies to the full range of the boom’s movement. The “restricted” capacity (1000 pounds) applies to a limited range, typically at higher elevations and with less extension. Exceeding these limits is extremely dangerous and can lead to equipment failure.

THE RIGGING PLAN 

Traditionally, lights would be mounted on “candlesticks” (vertical speed rail) attached to the Condor basket. However, due to the weight of the Nanlux cluster and the cage, additional support may be necessary. Brendan outlines a plan that involves using 6-inch Module X truss, strapped to the bottom of the basket, to provide a secure mounting point for the moving lights.

CALCULATING THE LOAD

Brendan meticulously calculates the weight of every component: speed rail, cage, lights, movers, truss, cheeseboros, cables, etc. This detailed accounting is essential to ensure we remain within the Condor’s safe operating limits. In this particular case, the total weight with the moving lights comes to 929.2 pounds. Without the movers, it’s 682.2 pounds.

THE TRADE-OFFS 

Because our total weight exceeds the 500-pound unrestricted capacity, we’ll likely need to operate within the “restricted” range. This may limit the maximum height we can achieve, potentially to around 100 feet instead of the full 120 feet.

FINALIZING THE PLAN: SAFETY, FLEXIBILITY, AND COMMUNICATION

The final stage brought together myself (Shane), Brendan, our key grip, and Tom, our gaffer, for a crucial discussion. We needed to weigh our creative goals – lighting that 150-yard stretch of road – against the very real practical limitations of the Condor, namely weight restrictions and potential height limitations. This is where the rubber meets the road, where the ideal plan confronts the realities of physics and safety.

And safety is always paramount. That’s non-negotiable. We would never compromise safety for the sake of a shot, no matter how ambitious. If the weight calculations or the lift’s inherent limitations prevented us from achieving our initial vision, we would absolutely adapt. That might mean scaling back our lighting package, perhaps using fewer moving lights or opting for lighter-weight fixtures. It could even mean modifying the entire rigging approach. Flexibility is essential in this business; you have to be prepared to adjust your plan based on real-world conditions.

This adaptability hinges on open and honest communication. The DP, gaffer, key grip, and, crucially, the Condor operator, must be on the same page. Everyone needs to understand the plan, the limitations, and the safety protocols. There’s no room for ambiguity or assumptions when you’re dealing with heavy equipment at significant heights.

In this particular instance, after reviewing Brendan’s meticulous weight calculations and the Condor’s specifications, we determined that operating within the restricted range was the only safe option. While this might limit our maximum height to around 100 feet instead of the full 120, we collectively agreed that this was acceptable for the specific location and the desired look. We proceeded with the rigging plan, confident that we had a solution that was both creatively effective and, most importantly, safe.

THE BOTTOM LINE: PLANNING, PRECISION & ADAPTABILITY

This pre-rig exercise demonstrates the complexities and considerations involved in using a Condor boom lift for night exterior lighting. It’s not simply a matter of sticking a light on a lift and sending it up. It requires careful planning, precise weight calculations, a thorough understanding of the equipment’s capabilities and limitations, and, above all, a commitment to safety. It also requires teamwork and clear communication.

This lesson is just a small glimpse into the world of production rigging. To gain a comprehensive understanding of rigging techniques, safety protocols, and the art of shaping light on a large scale, we invite you to explore the full Film Production Rigging course, available exclusively with a Filmmakers Academy All Access membership or as a one-time purchase.

You’ll learn from industry experts, gain practical skills, and elevate your filmmaking to new heights. Don’t just light your scenes — control your light, shape your world, and tell your story with power and precision.

NIGHT CINEMATOGRAPHY MASTERCLASS

This Condor rigging lesson gave you the how. Now, are you ready to see the why? In our Night Cinematography Masterclass, you’ll witness the stunning results of this very setup in action. We’ll break down how the principles of Condor rigging, combined with expert lighting techniques, create truly breathtaking night exteriors. You’ll see how the theory translates into practice, and learn how to apply these techniques to your own films. Don’t just learn about rigging — see the cinematic magic it unlocks! 

Get the Night Cinematography Masterclass now and transform your night shoots.