Before..........and after

Sails and fantail fitted at last, Wednesday 25th June 2014

After a bit of a wait for the ground to dry out again after a wet spell, we were ready to fit the fantail and sails.

The wind was initially a bit fresh, which made fitting the fantail slightly interesting (a large surface area to volume ratio=not very stable dangling off a cable). With another guide rope attached, however, the shaft was soon guided into its waiting bearings, and the bearing caps were swiftly fitted thereafter! At this stage the fan was left tied off, as we wanted to turn the cap manually. (The next day we tested it properly and it turned the cap from 90 degrees out of the wind, into wind with no problems.)

So, next came the sails. The first sail was lifted onto its stock and bolted/clamped into place. The 'empty' bit of stock was then lowered through the canister (the metal box at the end of the windshaft); thankfully it fitted. The second sail was then lifted and bolted/clamped to the stock. This was probably the most time consuming part of the day, as the two bolt holes could not be brought into alignment. It became evident that the sail needed trimming slightly to fit alongside the canister. This sorted the problem, and a bit of persuasion soon had the sail fixed in place.

After a bit of struggle getting the sails turned 90 degrees using the crane and a bit of leg power inside the cap (think hamster wheel), the process was repeated for the second pair of sails. These went on much more quickly (maybe we were getting the hang of it by now).

8 hours condensed into a few paragraphs!

We were back the next day to tidy up the wedging which locks the sails into place and to test the fantail. Longer term, the sails will be fitted with canvas, then we'll really see how she fares. All being well, the mill is capable of producing flour, but it is a very old machine, so we'll have to build up to that gradually. No doubt there'll be plenty of adjustments to be made along the way.

Just about to lift the fantail

A perfect fit

Fantail installed, now for the sails. (The paragliding enthusiast in me was trying to ignore the epic-looking sky at this point!)

Lifting the first sail onto the stock

Swinging the first sail over to the stock

Lining up the sail and stock

Almost there

Bolting the sail to the stock and getting ready to fit the clamps

First sail and stock dropped into the canister, now lifting the second sail for fixing to the stock

Repeat for the second pair of sails, and there you have it

Not a bad way to end the day

Even closer to sails going on...

Another step forward today; moving the stocks and sails from storage over to the mill. Actual fitting should be soon...

National Mills Day  Sunday 11th May

The mill will be open on Sunday from 11am until 5pm. We would be delighted to show you around. Come and have a look in the new cap, and for those with a head for heights, there's a great view from the fan stage!

Sailing along, part 2

So, more progress with the sails. All four were finished a while ago - we then moved onto making the stocks. These are the large timbers which fit into the end of the windshaft, and onto which the sails are fixed. Here's one being cut to size with our new saw - nothing subtle about working with sail timbers....

After all the sail timbers were finished, they were sent away for pressure treating with preservative. We then waited for a while (whilst working on another project) for the timbers to dry, to help with paint adhesion.

In the meantime, we laid the whips onto the stocks temporarily, to drill through both for the bolt fixings. We figured this would be a lot easier on the ground than half way up a mill in a hoist. It was still a hassle though, much thanks to our helpful farmers for the moving machinery.

Positioning one of the whips for drilling

More recently, we have moved onto painting the sails. Very smart they look too. Shouldn't be too long now before putting them up. Watch this space.

Sailing along

We are now well into making the first sail for the mill. First came planing and dimensioning of the smaller timbers, for the sail bars etc. Then came the not insignificant task of getting the 30 foot plus main timber (or 'whip') into the workshop. Copying the remains of an original, it was dimensioned and tapered, reading for chopping out the mortices for the 24 sail bars. These were all at different offsets and angles, to give the sail its 'spooned' shape, which helps catch the wind.

Here is the whip with the sail bars fitted.

After this, the lead boards (visible on the right hand side) were fitted. These smooth the airflow onto the canvas (when it's fitted).

Next job will be the long members which run at ninety degrees to the sail bars (uplong and hemlath). Unlike the whip, these will be made of several lengths spliced together (one piece is visible lying on top of the sail, on the left side).

Meanwhile, we have made some minor modifications to the outside of the mill itself. We have noticed that, in driving rain, some water has been getting in just above the lintels, mainly at the upper windows. It is a weakness with timber lintels against stonework; as the timber dries and moves, a slight gap inevitably forms. There was no evidence of any hoods having been fitted to these windows originally, but we have decided to fit small strips, with lead flashing, to help prevent this water ingress. It changes the aesthetics of the tower only slightly and, more importantly, it should help prolong the life of the mill. Any water entering here could affect the new spliced beam ends which were fitted at the start of the project (perhaps the originals were so rotten, at least in part, due to a lack of protection over the lintels). The usual problem; where do you restore faithfully, where do you improve, where do you renew. It isn't easy, but we try our best......

A long overdue update

Hello again. Well, lifting the cap onto the mill already seems like a long time ago and the summer has been well spent. Work-wise, we were away for a while, painting the sails of Danzey Green windmill, at Avoncroft Museum, Bromsgrove. Back at Great Haseley, we have spent some time setting up the drive gear from the fantail, so that the cap will turn into wind. A few teething problems, mainly due to lack of space, but we are getting there. Also, we have made lots of progress building the brake wheel. This is the large gear which is fixed to the windshaft, and has a brake around its outside rim, hence the name.

Here, the segments of the brake wheel have been cut and joined together.

The next step was to mark out the 90 mortices, into which we would fit the cogs. These were very deep mortices, tapering and at a slight angle. Not easy.

Here we are with the cogs driven in, and by now the segments of the wheel have been bolted together.

Next, the 'clasp arms' were fitted, four on each face of the wheel. These will box around a square portion of the windshaft, so that the brake wheel can be wedged solidly into place. In essence, the whole drive for the stones come from this interface, so it has to be strong and accurate. In this image, the four arms on the underside have already been fitted, and two on the upper face are in position. These two were the only salvageable originals, and even they are a bit wormy - we shall see!....

Once complete, there was just the trivial task of taking it all to bits again, taking the pieces to the mill and rebuilding it in position around the windshaft. Unfortunately levitation is not one of our skills, so the last step was a bit awkward.

Clasp arms wedged into place

and the wheel built around them.

It will take some time to fine tune the position of the brake wheel on the windshaft, and the position of the wallower (the horizontal gear with which it meshes). It also looks like the brake wheel cogs will have to be shaped slightly, to get a perfect mesh. So, we are getting there, but slowly.

PS. Other news; we have just taken delivery of timber for the sails. So that'll be more morticing then.......