Thread Number: 38734  /  Tag: 80s/90s Vacuum Cleaners
Now I did it! Royal PowerCast
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Post# 411539   7/15/2019 at 16:18 by fantomfan57 (Central Texas)        

found at a ST. Vincent de Paul thrift store. First glance shows a lot of wear on the handle and one front wheel is busted. I have not plugged it in yet.

It and an Electrolux in a box were both 30% off. I won't take them back even if they don't work.

I can already see parts are non-existent to expensive.

So a front wheel and a replacement handle grip. I think this one is missing a front bumper.

Post# 411544 , Reply# 1   7/15/2019 at 20:03 by fantomfan57 (Central Texas)        

The cord, cord hooks and pedals (operate) look good. I may not have the U bags, will have to check Tues. when the garage is cooler.

The wheels are not as wide as the regular metal uprights. I have a pair and think I will switch out one from the back to match and put the wider ones on the rear.

I will fire it up Tuesday.

Oh, and the bumper is there after all. Dunno why I did not remember that.

Post# 411552 , Reply# 2   7/15/2019 at 23:05 by rivstg1 (colorado springs)        
I'm envious

rivstg1's profile picture
I want one too....haven't even SEEN one up personal. I want one b/c its unusual....and I like Royal. I"ll be following your thread to see how it develops

Post# 411553 , Reply# 3   7/15/2019 at 23:50 by electrolux137 (Land O Plenty USA)        


The Powercast models are highly styled and retro-looking. But they're beasts -- heavy and unwieldy and hard to move around. This series of machines was a big flop and a huge money-loser for Royal. And that's a pity because they really are beautiful -- and powerful.

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Post# 411554 , Reply# 4   7/16/2019 at 00:03 by Lesinutah (Utah)        

lesinutah's profile picture
I remember Blackheart had and sold one. He said it wasn't powerful and live up to his expectations. It's cool looking but royal metal uprights are the royals I like.
Let us know how it is.

Post# 411592 , Reply# 5   7/16/2019 at 21:10 by fantomfan57 (Central Texas)        

I plugged it in and both Motors sound great. Cleaned the brushroll, and found the belt in excellent shape. So everything checks out, except of course the wheels. These are the consistency of a block of cheese. I wonder what happened to make them turn to junk. Exposure to the sun?

Decided against Royal wheels as the shaft is larger on the PC. So my second choice will work. Generation Kirby wheels. Same hole size and diameter, except I had to alter the two I found in my stuff using a Dremel. All that is left is replacement retainer caps. Off the Home Depot.

The front wheels will be a bit more of a challenge. Beside the fact that I don't have another pair, but they will have to be altered a different way to provide the correct (and different) clearance than that of the rear wheels.

I found a package of Dirt Devil U bags in my stash, so that is set.

Next step, until I get two more wheels is to wipe everything down.

I remember somewhere reading that the handle was weak plastic. The rubber cover on the handle is worn away, but this handle is metal.

More to come. I will try to remember to take some pictures.

Post# 411594 , Reply# 6   7/16/2019 at 23:10 by Lesinutah (Utah)        

lesinutah's profile picture
If you drill out center of Kirby wheels diameter of the shaft should fit.

Post# 411606 , Reply# 7   7/17/2019 at 05:19 by fantomfan57 (Central Texas)        

No need to drill the center of the wheels to go on to the shaft, they fit already. On the set I have, I shortened the center collar so it went on deeper. That allows me to use a new retainer cap to hold it on.

The front mounting will require drilling a wider hole partially in to leave room for the next pair of metal retaining caps. But, I don't have the wheels to alter yet.

Post# 411614 , Reply# 8   7/17/2019 at 15:23 by fantomfan57 (Central Texas)        
It has functional wheels...

Here are the results, all Kirby wheels because that is what I had that fit. Everything works, but I will still have to see how easily it maneuvers and cleans.

Next up, clean and disinfect. I can tell you right now, getting at and cleaning the hose that comes from the brushroll housing to the main unit, will be an adventure.

Does anyone have a copy of the User's Manual or know where I can get one online?

Belts and brushrolls are all I found available. So if anything breaks, this baby is only good for parts.

Thanks for looking!

  Photos...       <              >      Photo 1 of 3         View Full Size
Post# 411616 , Reply# 9   7/17/2019 at 16:01 by Lesinutah (Utah)        

lesinutah's profile picture
Is the body silver plastic or metal. It's pretty sweet looking I must say close up. I did think oreck magnesium was cool until I seen how gutless it was. This looks pretty sweet.
Thanks for answers. I'm curious and most people would have taken me for being smart ellic.

Post# 411669 , Reply# 10   7/18/2019 at 18:07 by fantomfan57 (Central Texas)        
Hey Les,

I don't think questions are bothersome. I welcome all questions from everyone.
To answer your question, most of the upper body is plastic, the lower housing is metal.

I wanted to add a solution I applied today. The bumper was shredded at each corner. I first crazy glued some of the raised surfaces to get them as flat as possible.

Then I found a old used rather large rubber vacuum belt, cut it, made some alignment marks and then Contact Cemented it over the entire front and part of each side to conceal the damage and provide a new bumping surface. I will include a picture later.

Now I am faced with the daunting task of finding a way to expose one end of the front hose to clean it out.

First, I need to completely clear my work bench.

Post# 411673 , Reply# 11   7/18/2019 at 18:28 by Lesinutah (Utah)        

lesinutah's profile picture
Drain snakes work for cleaning hose. I have but wouldn't recommend is water. You put hose in one end and seal with hand it eventually unclogs the hose. I run water through and seal one side) I do this a few times making sure the hose is free of debri. If you have a compact or shop vac with a blower they work.
Just pressure eventually unclogs hose.

Post# 411717 , Reply# 12   7/19/2019 at 05:39 by fantomfan57 (Central Texas)        
The hose....

I am referring to is the one exposed when the PowerCast is tilted back. Sends dust from brush roll area to the main the dust bag. I can see that it is dirty. I have seen a picture of the hose itself and think I found the screws to take the top cover over the brush roll area.

But like I said, I have to clear my work bench...too much "stuff" in the way to comfortably work on the Royal.

Post# 411783 , Reply# 13   7/20/2019 at 17:51 by fantomfan57 (Central Texas)        

I tried to keep track of all the screws and where they went. Obviously I slept a couple of times from when I took them out and began reassembly.

First I noticed 2 extra screws meant to be used in plastic. I figured out where they went and reassembled the vacuum again to find that now, I have two extra machine screws.

Baffled, I disassembled once more and could not find where they go. I will try again later this coming week.

Puzzled in Texas.

Post# 411796 , Reply# 14   7/20/2019 at 19:35 by Lesinutah (Utah)        

lesinutah's profile picture
If it's a bypass unit which royal commercial was bypass. The hose will disconnect outside power nozzle probably on the right side. The left side would be the end of the hose and could be disconnected there.
The hose by brushroll goes directly to the bag. You can take bag off and use a blower and it will clean out. If it has this bag housing blow it out too.

Post# 411803 , Reply# 15   7/20/2019 at 20:01 by fantomfan57 (Central Texas)        
Hey Les,

I think you are talking about a completely different Royal model based on your suggestions.

This is a Royal Powercast. Does not look anything like the other Royal metal upright models.

Post# 411804 , Reply# 16   7/20/2019 at 20:39 by Lesinutah (Utah)        

lesinutah's profile picture
The royal I think was royalaire orange similar to Hoover commercial vacuum. It was a shoddy vacuum.

Post# 411820 , Reply# 17   7/21/2019 at 00:46 by MadMan (Chicago, IL, USA)        

madman's profile picture
They always put extra screws in these things :P

Post# 411824 , Reply# 18   7/21/2019 at 01:58 by fantomfan57 (Central Texas)        
"Extra screws"

That is funny, but I will find out where they go. After all, I did not completely disassemble this unit.

Post# 411841 , Reply# 19   7/21/2019 at 11:00 by kirbyklekter (Concord,Ca.)        
"Extra screws"

I've had screws fall out of vacuums during dis-assembly and dat-assembly, (sorry), that didn't even go to that machine, someone just thought it was missing and added a screw where it was never intended. So there's that.

Post# 411847 , Reply# 20   7/21/2019 at 14:36 by Lesinutah (Utah)        

lesinutah's profile picture
I thought he was talking about me. Lol jk

Post# 411857 , Reply# 21   7/21/2019 at 21:16 by fantomfan57 (Central Texas)        
And now the end...

I quickly found the two locations where the screws came from. It was hard to find right away, but I did. So now I have completed the restoration (except for the incorrect wheels).

I have started and finished refurbishing an Oreck Magnesium that someone clogged full of drywall dust and paper. Took some doing, but I purrs like a kitten. Just waiting for my bags to come in the mail.

Thanks for reading this extended post.

Post# 411882 , Reply# 22   7/22/2019 at 10:18 by rugsucker (Elizabethton TN)        
"--keep track of all the screws--"

I most cases I will put a screw back in the same hole of same part as soon as I take it apart.I don't always know if I have to stop to check another or wait to reassemble.Some such as 4 motor screws on 1400 Eureka UR look same but one is different length for a reason.It may sound like double work but I spend no time wondering which screw for which hole or are there too many or too few.
Royal Powercast--
Great find.Very rare and interesting.One of the few modern vacs I would want in a collection and sometime use.

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