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There will be so many pyrotechnics onstage during Hale Centre Theatre's United States premiere of "Zorro" that all 300 of the show's house-made costume pieces were designed to be fireproof.

Those costumes were also inspired by the paintings of 18th-century artist Francisco Goya, but that's getting ahead of our story.

Hale's technical crew collaborated with pyrotechnics experts and Las Vegas illusionists to design the show, complete with torches, fireballs and grand entrances involving flames. "Zorro" also includes two live flamenco guitarists and a score written by the Grammy Award-winning Gipsy Kings.

The show debuted in London in 2008 and has been produced in 10 countries. It's the story of young Diego, who runs from his responsibility of leadership in a Los Angeles Latino community to the wilds of a Gypsy band in Spain in the 1880s. Entreated to return home to save his father, home and the love of his youth, he becomes Zorro.

HCT received rights to "Zorro" after executive producer Sally Dietlein approached John Gertz, president and founder of Zorro Productions, who developed the musical and collaborated with Stephen Spielberg on two "Zorro" films. After watching HCT's production of "A Tale of Two Cities" last March, Gertz began collaborating with the Utah company on the show's premiere.

HCT's "Zorro" is directed and choreographed by David Tinney, with Casey Elliott and Derek Smith alternating as Zorro, and Megan Heaps and Jacquelyn Jones as Luisa.

Elliott says between the special effects, fencing and dancing, he's had his work cut out for him. His experience includes lead roles in the company's "A Tale of Two Cities," "Joseph and the Amazing Technicolor Dreamcoat" and "Aida," which led to the Broadway national tour and the first China Broadway tour of that piece. He says he's learning some new tricks in this show. "I drew a sword in 'Aida' but that's it," he jokes. "But I've watched a lot of movies."

The key to rehearsals and the two-month runs at HCT, Elliott says, is that actors need to get into a groove and practice enough to give themselves stamina. "It's also really important to make sure you get enough rest and that you're not oversinging," says Elliott, who works by day as the CEO of a start-up company that provides education technology for teacher training.

Elliott is looking forward to debuting the musical to audiences of all ages, including those who grew up with the Disney TV series in the 1950s. "Back then it was one of the most popular shows, so I'm very excited to re-create the character," he says. "My mother-in-law has all the seasons on DVD so I've watched them all. My kids are incredibly excited to see the show. I have a 6-year-old son, so I've been teaching him all the parries and moves. I'm sure he'll be doing them from the audience."

Elliott's co-star is Megan Heaps, who is appearing in her fifth HCT show, but finds "Zorro" a different challenge. "Not only do we have to learn a new style of dance that is completely and literally foreign to all of us, but we have to sing in Spanish at the same time," Heaps says. "And I have never been in a show with so much fire."

Heaps hoped to perfect her sword-fighting in the show, but it's not part of her role. Instead, her character gets thrown around the stage by Ramon, Zorro's brother.

She did sword fight as Marguerite in HCT's 2009 production of "The Scarlet Pimpernel" and remembers one performance where her finger was sliced onstage. "[I] bled all over my costumes, the stage and other cast members," she said. "I think the audience was more in shock than I was, that I kept going to the end of the show. But a trip to the emergency room, 17 1/2 stitches later, and an awesome scar and story to tell, I still love sword fighting."

Costumes were designed by Tamara Clayton, who worked with three pattern makers and a 14-person crew. "I tried to copy some of the Spanish elements of Goya's painted clothing into my Gypsies," Clayton says. "I drew a lot on his color palettes. I liked the element of passion and depth in his paintings. There are a lot of layers to all costumes in this show. The Zorro character will be a lot to manage because he has an 'alter-ego' and will need to switch back and forth often."

Tinney, who has directed three shows at HCT, said "Zorro" has provided another kind of education, as the show has been transformed to an in-the-round arena stage. "I have never done a show with flamenco, magic, stage combat and pyrotechnics, but to do a brand new show with all of these elements, and to still try to focus the story, has been an exciting challenge," Tinney says.

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Crazy like a fox

Hale Centre Theatre presents "Zorro."

When • Feb. 16 through April 11, Monday through Saturday at 7:30 p.m. with matinees each Saturday at 12:30 and 4 p.m.; no matinee performance March 31.

Where • Hale Centre Theatre, 3333 S. Decker Lake Drive, West Valley City

More info • $15-$26, at 801-984-9000 or halecentretheatre.org