KSE Signalling Project

After much preparation, we are now ready to install the final string course on which, the windows, and ultimately the roof, will sit. Although these are large and very heavy, we need to make sure there is no chance of movement when weight is applied. This photo and the ones below show the west-facing wall being built up and the repointed back wall. Consequently, we have been busy mounting various keys into the backs of the pieces of stone which, when enveloped by the concrete of the wall, will give us an immoveable base on which to mount the windows and then the roof. We have also begun to tackle the remaining panel of stonework on the west-facing wall which continues from where the windows finish to the rear wall and also rises to meet the cream bricks of the yet to be built gable end. So a lot is happening and there is still a lot to do so, as soon as there is more progress, I look forward to telling you more very soon!

(Apologies for the Hot Shots reference with the title...) As a change from digging holes, this entry looks back at the Central Division (CD) components and what has happened with them. The arm weight we had originally hoped to cast from with minor attention, then machine out afterwards was not so simple, and instead required a pattern making to accommodate the voids / holes / undercut / pockets. Going down this route has caused extra outlay to have the pattern made, but brought down the cost of producing the components, as they will only require basic fettling and drilling as opposed to awkward machining. The more of these we have done, the greater the saving... Original arm weight (Right) Pattern for full size arm weight (Centre) Pattern for small (subsidiary) arm weight (Left) At the same time, we had a pattern made for the smaller (subsidiary) CD arm weight. These have now been completed, delivered to the foundry and successfully cast from! The extra lumps and hollows relate to wher...

Derek ‘Del Boy’ Payne The stonework on both the east and west-facing walls is now at a height to receive the final, second, ‘string’ course on which the window frame will sit. All that is required now is to bring the front wall up to the same height which will allow us to settle the large, heavy and expensive sections of stone comprising the machine-cut ‘string’ course into place. Derek ‘Del Boy’ Payne has begun the mind-numbing task of pointing the rear wall beginning with the inside face which, although it is going to be plastered, requires fresh mortar in all the joints. If he manages to keep his sanity, then he will begin the task all over again on the other side thus sealing it from the weather and finalising the very satisfying rejuvenation of this 160-year old wall. With snow forecast, it is presently uncertain when we will be on site again. Hopefully not too long and I look forward to reporting further progress soon.

With the rear wall now totally secure and awaiting pointing, our attention returns once again to the facing stonework. In particular, that of the east-facing wall which will eventually contain the operating room doorway. Anxious to provide sufficient room for wheelchair access for our disabled friends, the first blocks of stone were set down on the flat, solid, sandstone step we had installed earlier. This provides a pleasing combination of a sufficiently wide doorway with no step up, or down, which ensures easy access for all. Continuing on with the adjacent stonework up to the front corner of the ‘box saw us make excellent progress throughout the day, with the door opening now clearly defined and the wall almost up to the final ‘string’ course level. Meanwhile, the stonework on the west-facing wall is also up to ‘string’ course height and just waiting for all the fiddly levelling-up pieces to be added to the top to give the nice flat landing we require for seating the ‘string’ course...

This post comprises two reports from Bob – the first of which highlights the ‘joys’ of working outside in the ‘delightful’ Cumbrian weather at this time of year. The second describes work on one of the better days! The successes of Monday 15th and the elation of taming the rear wall were completely negated by our efforts on Friday 19th to get any meaningful work done at all as our water supply resisted all attempts to thaw it out – hot water and blowlamps proving no match for a Stainmore winter. The bulk bag of sand was frozen into a rock-solid block which even a determined attack by Andrew (with a pick axe!) did little more than reduce it to a selection of large sandstone rocks. So, after 4 futile hours of trying to start work, and with frozen fingers and empty bellies, we had to give it best, go home and await the thaw, but rest assured, we are not easily put off and we will be back! Yesterday (24th), as winter released its icy grip, at least for the moment, we were able to continue ...

Just a quick update from yesterday's efforts in the cold. We completed bolting the a-frames (and rollers) onto the stools we planted previously. We had hoped to complete the infilling around the stools and drop some rods in as well, but the ground was frozen! Will at work, bolting the a-frames onto the already-buried stool. The stool cannot be fully buried until these are fitted, as you can't physically get the bolts in, since the ground is in the way here! In an ideal world we would have fully assembled the rollers and A-frames BEFORE planting the stools, but that wasn't possible for a number of reasons. North Eastern Railway, Northern Division castings for replication. Kirkby Stephen did feature some Northern Division signals in the area, and the Eden Valley certainly had some! The lattice posts we have on site, one of which that will be used in this scheme, require these fittings. We also gathered the NER Northern Division components together, to take to the foundry for...

On Saturday, we finally began to tackle the elephant in the room (the rear wall) which has lurked in the background since we began this project and has been the subject of much debate on the best way to repair it. Our original intention was to rebuild the inner skin completely in blockwork to eradicate a bulge in the middle, and a slight lean at one end, but a visit, and some expert advice from our local professional builder, Paul Thompson, indicated that such a drastic measure was not required. Instead, we could undertake the necessary repair by more simple means. Consequently, we have been able to fix the lean on the corner by re-aligning all the stones in their original position, pointing all the joints and, finally, pouring a liquid cement mix into the core which will consolidate all the stonework on this corner. When the building is finished, this corner will form one half of the main doorway into the signal box. The bulge in the middle of the wall will be the next job and ever...