Because thepressurized air pushesagainst mostof

male push-to<onned thesurface areaofthecastermounting plate,a highlevel

air hose fitting of liftingforceis generated witha relatively
lowpressure.
Thecastermounting platehasa bit lessthan25 square
inchesof surfacearea.Usingair pressurized to 10
poundspersquareinch(psi)ttreAir-tiftCaster hasalift-
air inlet hole ingforceofwellover200pounds[Pressure (psi)x Area
(sq.ins.)= Force(lbs.)I.
I testedtheAir-IiftCaster underincreasing air pres-
tlz inch PVCtop plate sures.Atabout40psi,givingtheunitalmost1000lbs.of
liftingforce,therewasrors [rrlgrngof ilretopplate,but
no air leakage. A substantial leakbetween thetopplate
andthe diaphragm developed at about55 psi, but the
unitneveractually "blewout."Evenwhenshock-tested at
+tlrc inch pure gum
120psiit onlybulgedandhissed, automatically relieving
rubber diaphragm
excess pressure.
I havebuilt80Air-Iiftunitssince1989,andI have
neverhada unitfailin use.Maintenance consisted of oc-
casionally removing thecaster/caster mounting plateas-
semblyandair-blowing out anydirt or debris,usually
doneonlywhenI wantedto changeto a differentsize
caster.
In September, 1993,I built 32 Air-Liftunitsand
spentiust under $300on materials-Pvcsheetand
pipe,diaphragm rubber,air inlet hosefittings,screws
and castermountingbolts (but not the castersthem-
-3leinch PVCcastet selves)-lessilran$tOfor eachunit.A scenicunitfitted
mounting plate with Air-LiftCasters canbe connected directlyto your
stageair qmtem, usinga longhoserunningoffstage to a
regulatorsetat lf 15psi.Butfor a self-contained, truly
- standardswivelcaster portablescenicunitI recommend purchasing thefollow-
ng: t l25 psipressure storaget nk (about$30),a pres-
sureregulalor ($10), anda, j-way,2-position pneumatic
valve(about$20).
-retaining ring Listedbelowis thestep-by-step cutting,machining
andassembling process I usedto build32Air-IiftCaster
units.Alternative toolscan be usedin placeof those
listed(e.g.a table-mounted routerinstead of theshaper,
or a stationary beltsanderinsteadof thestationary disc
sander).

CIITTING
l. Thetopplateswerecutft,om% indHhick PVCstreetto 7 indresby7 indres,usingtheable saw.

2. fte cylindenwerccutfrom 6 indr diamete4sctredule

80 PVCpipeto lzh indreslong,usinga V-blockprpecuningiig
on thebandsaw.

3. Ihe castermountingplateswerecutfrom3/ainch-thickPVCsheetto a 5slainchdiameteq

usinga circlecutieron the
drill press.

4. A % indrthick sliceof 6 indr, schedule

80 PVCpipefor vmscutfor eadrreainingring,usinga V-blockjig on ttreband
saw.A 3indilongsectionofthecircurnferenceofthisslicevascuta{ruywiththebandsaw.

werecutfrom t/roinch-thickpuregumrubberto a 6A indr diameter,

5. the rubberdiaphragms usingshopscisson.

r4 SU M M E R 1 9 9 6 TD&T