In a day less than what we initially expected, Erik and Ronald successfully lifted the cap frame, modified all 12 cast iron sliders, and safely lowered the cap frame back into place. This process required the use of low-profile hydraulic jack, lent to us by Mike Mortensen of Mike's Welding in Kimballton, and dozens of metal shims that Mike cut for us from strips of flat bar. One by one, Rik and Ronald jacked up the cap frame just enough at each of the 12 contact points to remove each of the cast iron feet, held in place by lag bolts that ranged from 4 to 6 inches long. During this process, each point had to be carefully measured so Erik could calculate where the second set of holes would be drilled on each iron foot. 

As the sliders were removed, we began transporting them to Colton Juelsgaard's machine shed located outside Elk Horn. Colton's milling equipment gave us the ability to drill new holes with exact precision, and although it took a few hours, having access to state-of-the-art equipment saved us considerable time. 

While Colton continued to drill into the new holes, Erik and Ronald began replacing the finished sliders back into the cap frame. Again, this was a slow process, as it is important to jack up the frame in very small increments while also trying not to rub all of the grease out of the track. 

As we lowered the cap frame back down, a new problem emerged that Erik and Ronald recognized right away. Moving the sliders into new locations had changed the distribution of contact points between the mill's hat and body, causing excess pressure on the horizontal axle (windshaft) that bridges the cap frame front to back. If this pressure wasn't relieved, the shaft would run the risk of eventually snapping.

To relieve this pressure, Erik and Ronald had to remove a stubborn bearing and cut some additional space into the white oak frame, taking the downward pressure off the back of the axle. This process took a few hours and was among the more tedious jobs we encountered, but we are grateful to have had such experienced millwrights with us to catch it and fix it before irreparable damage was done. 

TIGHTEN THE WOODEN COGS

Besides Erik and Ronald, we also had the privilege of having Logan Aalbers join us for the first couple of days. Logan lives in Pella where he is part of the crew that maintains the Vermeer Windmill. 

While Erik and Ronald worked on the cap frame, Logan followed Erik's guidance on how to inspect and tighten the wooden teeth on our spurwheel and brakewheel. Many had become loose over the years, and it was only a matter of time before one might fall out while the mill is running. 

Logan also stuck around to help Shaun disassemble to old friction wheel for the sack hoist, which we moved to the ground floor for a new exhibit. This proved to be a challenging job. Unfortunately, the wheel was so rotten that we had to cut part of it in order to remove it without causing further damage, but thankfully the cut isn't noticeable in its new display. And since we couldn't take it apart, it took all four men to get the bulky wheel down to the ground floor.

We're thankful for Logan volunteering some of his time with us, and he left rewarded with some treasured experience alongside Dutch millwrights as well as some souvenirs including an old tooth once used on the brakewheel. 

REPAIR THE WINDSHAFT

RE-SHIM THE WINGS

While Ronald worked on the wings, Erik began constructing the new axle and wheel for the brake chain we planned to add. Since we had extra time, Erik was able to construct a more authentic pulley system. It was a lot of extra work, but we had plenty of time to get the extra materials and plan out the project around other items. 

Instead of simply redirecting the interior rope pulley that guides the brake beam up and down, Erik devised a new axle out of the white oak pieces. Using a length of iron shaft from Mike's Welding, Erik constructed an axle with two distinct shapes. A square end to be fit inside the wheel, and a rounded part to hold a length of rope. This axle would rotate with a secondary wheel tethered to the cable that would be used to operate it. It is a dual-weighted system wherein the weight of the chain (about 50 feet) creates tension on one end, and the weight of the brake beam (further weighted down with iron or stone) pulls from the opposite end. The operator's chain is wrapped around the wheel, and when engaged, the wheel coils the chain. Like the sack hoist system, the rotation of the wheel corresponds to a rotation in the axle, and by tying a rope to the axle, the energy is redirected to raising or lowering the weighted brake beam. 

To disengage the brake, the operator pulls the chain, rotating the wheel and axle clockwise. The rope coils around the axle, hoisting the brake beam upwards until it clasps into a hook towards the top of its path. We'll be adding video footage of how this mechanism works to our virtual tour in Spring 2025. 

Finally, Erik designed an authentic wooden ball that would be used as a gripping point on the chain. We gave the drawing to Mike Howard who milled a few pieces on his lathe. Their positions are completely customizable and they make the chain easier to work with in the cold. 

We're especially glad to have this addition. Not only is it authentic to how these windmills are constructed, but it also makes the windmill safer and easier to operate. Full control of the mill is now possible from the second floor without having to climb into the cap in the event of a problem or emergency. 

NEW GEARSHIFT FOR STONE NUT

There isn't really a technical term for this mechanism, but we'll just call it a gearshift as this is what it does and what most people can relate to. When a windmill is built and fitted with stones, the stones are not engaged by default. These machines are built to move in the wind, and this movement can damage or ruin stones if they are left unattended. That is why the stones are generally attached by additional gears that can be engaged or disengaged as needed. 

When the builders erected this windmill in Elk Horn, the gearshift was one area that was not covered by the model and requires some experience in milling to understand. They figured something out that functioned, but was always awkward for one person to use, and inflexible to the changes in temperature and humidity that cause different pieces to move around. 

With the use of a large 6"x8" pine beam gifted back to us by Chris Fredericksen, Ronald devised some alterations to this system that allowed for a more controlled motion of the stone's iron gear wheel. The new system functions solely with the use of a large wooden wedge that can be added or removed depending on which position the gear needs to be in. It is significantly easier to maneuver without the help of a second person, and also ensures that the iron teeth won't touch the iron of the spur wheel if the parts shift around again. 

NEW FRICTION WHEEL FOR SACK HOIST

While Ronald worked on the new gearshift mechanism, Erik began installing the new friction wheel. This required making more new shims out of white oak before we went to fit the wheel into place. 

Like the old wheel, this wheel had been fabricated out of white oak and was considerably heavy when put together. Unlike the old wheel, however, we were able to install this one in its separate pieces and assemble it while we went, making it much easier to handle.

After all of the new wedges were installed onto the drive shaft, Erik and Shaun began to assemble to new friction wheel above the shims. Once together, the wheel would be lowered onto the shims and fastened into place.  

*We want to thank Gene Thomsen of Old Danish Workshop, just across the street from the mill, for allowing us the use of his woodshop and tools. A number of clamps were needed to hold the wheel's pieces together while we assembled it and thankfully Gene had everything we needed. We always appreciate his help. 

GREASE BANK INSTALLATION

Fabricating and installing the new grease bank took a little longer than expected, but thankfully we had plenty of time to spare. Since Mike's Welding regularly builds these systems, we designed a hub for Mike to build and used his hose lines to build the system on the fantail. The upside of this is that the materials we used a high quality and will last a very long time. The downside was that the hose could only be cut in Mike's shop, which meant we had to be rather precise with our measurements to get it right. 

As a result, Erik and Ronald took time to measure out each grease line before their short break and vacation across the state. While they were gone, Mike built the hub and began cutting the lines we needed. 

After their return, Erik and Ronald installed the lines one by one on the fantail. These lines all meet at the hub mounted inside the cap, where grease can be pumped through the system on a regular basis to keep everything working smoothly. 

*We are especially thankful to Mike's Welding for their invaluable help with this project. Having access to these materials and skills locally made this project go much smoother. 

BALANCING THE FANTAIL

This was a project we didn't even know we needed, but we're thankful it was done. After Erik and Ronald were finished installing the grease bank, they took some time to inspect the fantail and fix a couple of things. This included repositioning the upper gearbox which had been sitting at a slight angle for some time. It also included rebalancing the fantail blades so they turn as efficiently as possible when the wind changes direction.

They also made a thorough inspection of the gearing and the blades. There are a couple of wooden pieces that will likely need to be replaced in the next year or two, but the rest of the system is sound and can be easily maintained thanks to the addition of the grease bank.

REPLACE A FLOOBOARD

We were told that Erik and Ronald often save the most difficult jobs for their boss, Morten. While Erik and Ronald were out on the lift working on the fantail, Morten cleaned up the tools and sawdust and even replaced a cracked floorboard for us on the third floor.

DRIVE THE MILL

The last thing to do was put the mill to the test and see how it performed and ground in high wind. We were fortunate to not only have great weather the entire time the crew was here, but also have some strong winds towards the end of their stay when we needed it most. This gave them plenty of time to drive the mill hard in high wind and really test the stones out in proper conditions that we don't normally have. 

The mill performed beautifully inside and out. The sails looked as good as ever cutting through the wind, and the stones actually produced some decent rye flour. They're not in the best of shape by any means, but thankfully they can handle a good session here and there when we need it.

FINAL TOUCHES

To celebrate a very successful two weeks of work, a special banquet was held on the crew's behalf at the Elk Horn Town Hall. Bill Peterson and Nate Kemperman graced us with the late-Dwight Lamb's famous Danish folk music, and Erik and Morten both shared their own perspectives on being in Elk Horn and the opportunity to work on a very special windmill. Shaun gave a long-winded presentation of the repairs and upgrades to the crowd and much appreciation was shared for our Danish friends as people bid their farewells. 

Shaun wrapped up on some of the final items in the following days. With a working sack hoist, the mill needed better protection of the ropes from unsupervised tourists. We also wanted to finally create a more accessible pathway to get to the stone gearing for when we want to grind. In the week after the crew left us, a pen and gate were added to the second floor and another will be added to the third floor soon. A small set of steps was also installed near the stones' gear to provide much easier access for future use. 

*Thank you to Amelia Juhl for taking great photos of the banquet for us. 

THANK YOU