Revolving Stage

[bobgaggle]

A while ago I posted a thread asking for help on building a revolving stage for a production of Jekyll and Hyde. These are some things I've learned:

1. Give yourself enough time. My high school's admin and various teachers were opposed to it because the revolve would impede the complete closure of some of the travelers. As a result, I couldn't get the thing done until a week before opening night.

2. Don't design anything around cost. Sure its cool to have a budget, but don't cut corners. I bought dumb casters partially because it makes the stage more diverse in its capabilities, but also because they were cheaper. BIG MISTAKE. Once we got the thing able to spin, all was well, but once we put a set on it, it made the loudest squeaking and groaning imaginable. We had to jack the whole thing (All 379 square feet of it) up and crawl under with a few cans of WD-40.

3. NEVER USE PARTICLE BOARD!!! Probably the worst stuff to use when building a multi-layered deck. I used two layers at 5/8" thick(glued and screwed) except that the one inch screws we tried to use stripped the wood every time we ran them in. another thing I didn't consider about particle board: it has a rough and a smooth side. I accidentally put the rough side down on the bottom layer, which just added to the rumble as at slid over the casters. Why did I use particle board? Because the good stuff was 4 dollars more per sheet. don't cut cost.

4. Once again, I cut costs. I mounted the casters to 2x6 boards, which i then adhered to the stage (wheels up). unfortunately, the top plate of the casters were 6" (and we all know that a 2x6 is really 1.5 x 5.5) I could only put two screws into the casters, but figured since the axle wasn't hanging over the edge of the board I'd be fine. We lost 12 wheels when positioning the deck. Had to jack up again and crawl under there.

5. Build your revolve in sections. I simply glued the whole thing together in one giant piece (24'x24'), slid part of it off the edge of the apron and cut out a circle (it took 50 people to shove it across the stage floor) I then had to get everyone to shove it off to the wings while I mounted the boards with the casters, then had to get everyone to shove the thing on top of the casters. BIG MISTAKE... one of the 12' boards holding the casters got ripped out of the stage and caught up under the deck as we tried to slide it on. Had I built the thing in sections and assembled on top of the casters, I'd have been breathing a lot easier.

6. And last but most important...DO YOUR FREAKIN' MATH!!!!! the casters I got had a load limit of 100 pounds. I estimate the deck to weigh 1600 pounds. (assuming 50lbs per sheet of plywood, 36 sheets would be 1800, and I guess I cut off 200 while cutting out the circle). I used 69 casters, so 1400 divided by 69 is 23 lbs per caster distributed over the entire revolve. Add det to that, (a giant pyramid like thing, more heavy stuff etc etc.) and bam, my casters are overloaded, or getting close to it.


Lessons learned, though. Sooner or later I'm sure i'll laugh at some strapping young man making the same mistakes as I just did.

[Van]

Did you follow the plans I posted on here ? If so maybe I need to update them with a few of these comments. All are good lessons learned but I wish I could have helped you through those.
Particle board or LDF is good for one thing, underlayment for carpet. It has to be layed in on top of a plywood surface to get the support it needs so it won't crack or punch through.
6" caster plate? typically I use a 2 - 3 " fixed caster with a much smaller plate on it.

I'm gonna go dig up those plans and re-post them with a spec sheet this time.
I'm sorry you had troubles, but thanks for sharing them with all.

[jrule]

I'm planning a 4 meter diameter revolve. I'm interested in your plans. I cant' find them in these threads. I understand the bottom part with the wheels. The top made in pie sections is sandwiched ? The Revolving Stage Company http://www.therevolvingstagecompany....g_satge_8.html
makes portable revolves with a curved channel under the stage. I'd like to make something like the Smartstage Co. http://www.smartstage.com/Turntable_15.577.0.html
Still can't figure how the top is made.

[lastmanstanding]

Thanks for the advice bob. I haven't done physics in a few years, but it looks like i'm gonna half to dust off that section of my brain. You make get the chance to laugh at a skinny young man who blazes whole new mistakes. maybe i'll post my errors here in another month.

[Conner8809]

i could use the plans also if you wanna email em?

[curtg]

Has anyone used a pallet turntable for the center support of a revolve?

[Van]

Originally Posted by Conner8809

i could use the plans also if you wanna email em?

Conner, PM me and I'll email you my turntable packet from work tomorrow. If you don't email me I'll forget as I have the attention span of a two year old.

[Van]

Originally Posted by curtg

Has anyone used a pallet turntable for the center support of a revolve?

I have not but I see no reason why with the proper modifications something like that wouldn't work. That being said it is a bit of an expensive option. A quick view of Graingers inventory shows several models of pallet turntable ranging inprice from just over $300. to just under $1,300. The center point of the turntable that I expouse the virtues of is made of two pipe flanges and two pipe stubs and some plywood, probably around $50.00

[lastmanstanding]

The mcmaster-carr website has just the open ring with bearings running for $300, though it doesn't look like there's any way to attach to it. the other turntable pallet they sell indicates specifically that it's not for people. it's also freaking 2000 dollars.

[bobgaggle]

as long as there's a demand...