Millwright’s Report on Projected Works

It was a bright and breezy Sunday afternoon in August last year. The south westerly wind was constant but not too strong. It was ideal conditions for letting the Sails idle on our open-day. Indeed it was a very busy afternoon for us, with more than 120 people turning up for a tour over the Mill.

As I was in the Cap putting the Mill to rest and packing up, I realised that the sight of the turning Sails had affected the number of visitors that afternoon. “If only we could have them turning every time the Mill was open!” I thought to myself. To achieve this would mean having the Cap capable of turning to wind once again. The likeliness of this happening before the Mill being restored was improbable - or was it?

Back in September 2008, I had surveyed the Mills Curb to see how out of level it was. The results showed that it was 3 inches lower on the S/W side than the N/E corner. This was due to the weight of the Sails being parked in the same place for more than 30 years. Structural distortion had taken place within the wooden framework of the tower.

The following Tuesday, with the aid of the Friends’ Voluntary Maintenance group, I set about doing another Laser Level  survey of the Curb. This concluded showing that the structure had not moved anymore over a 2 year period. I thought that if we could somehow put some timber packing blocks in-between the underside of the Curb Ring and the tops of the Corner Posts, we stood a pretty good chance of getting the Curb level. Now, the big problem is lifting the Cap up enough to take the weight off the structure, so that the Curb can then be jacked up and packing inserted above the Corner Posts. With the combination of the Sails, Stocks, Windshaft, Brake wheel etc. the estimated weight of the Cap must be near to 14 imperial tons, if not a bit more. One of our volunteers, Gerry Quest, who is also a volunteer at Coalhouse Fort, East Tilbury, had mentioned that he had access to a 50 ton hydraulic jack. If we could borrow this for a few weeks, then the job of jacking up the Cap would be achievable.  If we could also have the loan of some acro-props, we could support the structure on the 2 lower floors in the Mill. This would distribute the weight of the Cap down through the Mill’s main structure and prevent any further chances of structural distortion.

So, with the project now being feasible, I set up a meeting with Nigel Oxley from Havering Council. I produced a written report and a diagram explaining how we intended to carry out this work. With the winter drawing nearer, the ongoing task of replacing the weatherboarding on the Mill was becoming a job for dry, still conditions only. This project would be perfect for keeping us all busy over the winter months if and when we had clearance from the council.

The meeting with Nigel went well, but for a major project like this to take place, we would need to consult English Heritage. Nigel has regular meetings with Simon Hickman, who is the borough’s English Heritage representative, the next one being planned for December 14th. This was still 7 weeks away, so the task of repairing the Winding Box and reinstating the Transfer Shaft (at the rear of the Cap) took place. In the process of doing this, it was discovered that an oak supporting stud was completely rotten, along with the components that make up the external gear disengaging mechanism. Over a 6 week period, this work of replacing these items took place and the Transfer Shaft overhauled and re-fitted. This had been removed when the Fanstage had been repaired in the early 1980s, but never re-fitted. On the last Tuesday in November, with these components back in place and the bearings and gears greased up, the Fantail was un-chained and history was made. With no wind at all, we turned the blades of the Fan by hand and the Cap moved gradually. Knowing that the Curb was not level, we only turned it enough to move the Cap a few inches so not to damage the cast iron track on which it sits. Never the less, the first stage of the work was complete.

The following week saw the hydraulic jack and acro-props in place. These props were loaned to us by Bob Self, who had worked for my employer Vincent Pargeter. Nigel Oxley had aaranged with Simon Hickman to meet at the Mill on December 14th to discuss the details of the Curb levelling with Dennis and myself. Simon was very impressed with the work that we had carried out on the Mill and gave us verbal permission to carry on with the project. We had a week off at Christmas, and in the first few days of 2011 we received written confirmation from him, giving permission to continue.

We have managed not only to start levelling the Curb, but to turn the Cap by hand. This is so that the lowest section can be raised to the correct height without the added weight of the Sails bearing down on the Curb. Over the next few weeks we shall be finishing the levelling process, cleaning out the track and lubricating the whole system. By the time the next newsletter is produced in April, we hope to have achieved our goal, this being that the Cap will be turning to wind constantly for the first time in 60 years. If we are successful in doing this, not only would it increase the amount of visitors we get to the Mill on open days, but increase the donations we receive as well. It would also show we are competent in doing major repair work on our Mill, proving ourselves to be a worthy cause in the process of a Heritage Lottery Fund bid.

My thanks not only go to Simon Hickman and Nigel Oxley, but the loyal group of volunteers that help at the Mill every Tuesday. They are Brian Hayden, Gerry Quest,  Jeff Long, Mike Turner, Derrick Martin, John Critchall, John Reed and Ian Ross. Apologies if I have missed anyone out. Without them, none of this work could take place. It also goes out to Bob Self for the loan of the acro-props and Vincent Pargeter for employing me and giving me his full support on this project.  

Winter 2010/11
 

We took delivery of approximately 25 pieces of hornbeam for replacing the worn Brake Wheel cogs. This was donated to us FREE by The Woodlands dept. of Rochford District Council. My long- time friend Richard Bond, works over at Hockley Country Park as a tree surgeon. He had previously mentioned that two large hornbeams were being felled in January and offered us the timber if we were interested. After calculating how much we would need, we agreed to meet at the Mill at one o’clock. The delivery was on time and the timber safely placed in storage.
 

The following Monday I asked my employer, Vincent Pargeter, roughly how much un-seasoned hornbeam is to buy. Incredibly, it’s about £15 per cubic foot. We are now the proud owners of approximately £600 worth of green hornbeam.
 

In the last edition of the Newsletter, I gave a detailed account of how we intended to level the Curb of the Mill and try and get the Cap turning to wind again. I am pleased to report that on Tuesday 8th March, we officially achieved our goal.
 

The previous Tuesday we had left the Cap facing North, after another greasing up session on the track, bearings and winding rack etc. The weather was sunny and mild with a light South-Westerly breeze blowing. The Fan was put into gear and the chain removed. After about 5 minutes the wind picked up and the blades of the Fan started to slowly turn. The Cap was now turning wind assisted for the first time in 60 years! It was decided to let the brake off so that as the Cap came round, the Sails would start to revolve as they came into the prevailing wind. Some 20 minutes later, it did just that and history was finally made.
 

The same day, we were able to extend the Brake Rope, so that now the Mill can be started and stopped from the Reefing gallery. This is now as it would have been when the Mill was last working.
 

Another job that was undertaken that day was the removal of the unsightly chicken wire underneath the rear of the Caps petticoat. This has been replaced by easily removable boards (firstly to access the Winding Rack and Pinion for greasing, secondly to keep the pigeons out!) A great deal had been achieved in one day.
 

After discussing the success of the job, it was decided to not leave the Mill turning to wind constantly, but to just let it turn on Tuesdays and open days when I was available. The reasons are quite simple:- If a mechanical problem occurred whilst the Mill was empty, it may cause other problems within the Mills structure. Also, it’s a bit too much to ask of the ‘old girl’ before a full restoration programme takes place. Some of the structure does need attention after all.
 

I recently spoke to a gentleman (on the telephone) who worked as a volunteer at the Mill in 1950 for Hector Stone. Malcolm Hobbs intends to visit the Mill on a Tuesday in the near future, not only to share his memories of working for Mr. Stone, but to see, (wind permitting) the Mill turning. It is astonishing that this is something that he never saw in the year he worked with Hector. So it will be something he has waited a long time for.
 

I shall report on the details of his visit to us in a later edition of the Newsletter and also on any other work achieved at the Mill on a Tuesday.
 

Paul Kemp.