At the Grist Mill

Work continues on the grist mill. The sluice for the waterwheel was finishing in the fall of 2004. During one heavy rainstorm we noticed that the wheel was turning at  a rate of about 5 revolutions a minute. All we need is a stream. The plaster binding of a millstone was also completed and the second stone has now been set in place. The floor in millstone area has been set and no longer does it look like WW II had been fought there with no survivors. Work is now progressing on the mechanicals of the mill. On August 6,2004 Jim Morris started the design of the lantern gears that will eventually be set on the vertical shaft for turning the stones.

The lantern gear wheels have been put together. On April 29, 2005 the metal bands were heated and slipped over the lantern gear wheels.  The main drive gear wheel has been completed and is waiting for the delivery of the steel horizontal drive shaft. A vertical wooden line shaft is being prepared to receive the lantern gear. The next design project for the mill will be the fabrication of a paddle wheel gear which will also be mounted on the vertical line shaft. This design is in progress as of Dec. 2007.

Millstone prepared for plaster binder

It took three men and a mechanical aide to turn this one ton stone safely

Flooring laid out on trestle for sluice

One of two grain bins on second floor
The sluice is finished

The two Jim's with the main drive gear

Mike, Jim and Arnie fitting metal bands on the lantern gear wheel.

Finished lantern gear wheels

Finished Lantern Gear
Crown Gear and Lantern Gear ready for installation

The Crown gear and the Lantern gear pictured above have been installed on the vertical shaft and if the waterwheel turns then the shaft turns. The next step is to design and build the 72 inch diameter spur gear and 20 inch lantern gear to bring power to the stones. The spur gear will have 56 teeth and the matching lantern gear will have 13 candles. A model of the gear was assembled to check tooth spacing and it was determined that the above combinations will work. After a trip to New York State to talk to a gear expert - Jim Kricker with Roundout Woodworking we went out to acquire the necessary white oak for the gear and maple for the teeth of spur gear. While we would have preferred to get 4" thick white oak kiln dried planks none were available commercially. We would have had to buy green lumber and then wait the 2 to 4 years for the wood to dry. We settled on white oak planks which we will laminate together to come up to the necessary thickness. Basically the main spur will consist of 4 doughnuts - two 1.25 inches thick and two 2.75 inches thick. One each will be laminated to form a doughnut 4 inches thick. After truing up to round the necessary mortises will be spaced to hold the 56 teeth. A complicated project to be sure but one we feel we can do.

For a more complete photo album of the gear build follow this link: Spur Gear Photos

The first doughnut before glue up.

The first doughnut after glue-up.
We made two of the rounds in one day.

Carriage for the gear
Ready for teething and bolting
Pinion Gear

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