According to local recollections the water wheel last turned about 50 years ago. Since then it has rested on its rims in the slowly silting wheel pit. All that remains of its bearings are two half shells. The 12 foot axle and, crucially, its journals are heavily pitted with rust and need extensive restoration.

With a lot of help from our friends we took the old wheel apart over a busy weekend in 2006 and we had hoped to re-use the various bits after a bit of restoration and a coat of paint.

Dan and Kevin Harrison dismantling the old wheel 

However, during the dismantling it became clear that one of the hubs (pictured below) was beyond repair and also that several of the rim segments were so badly corroded, and in some cases damaged, that a new wheel was going to be needed.

Thanks to the Internet we found Paul McCairn who's helping us create a copy of the old wheel. Paul runs Bri-Mac Engineering in the Black Country and he is  supplying new bearings and wheel castings at an affordable price. We have created engineering drawings of the old wheel components and had new wooden patterns made.

 New rim pattern, painted with red varnish, ready for sand mould and casting.

The hubs and rims have now been cast and very soon we will be laying them out ready for machining and (initial) assembly in the works. 

One of the new hubs

One of 12 rim segments

Assembly on-site is still some months away as we have yet to clean up the axle and its journals and install new bearings. This is no mean task and requires tools and techniques, yet to be identified! Indeed, we are now thinking of replacing the long three-bearing axle, with two shorter axles, joined with a "flexible" coupling. This will make the whole job a lot easier and avoid the difficulty of aligning three bearings. However, it does add the new problem of having to separate the pit wheel from the old axle. It weighs half a ton and is nicely rusted on!

 Rusted axle journal in original bearing housing and bronze shell

Another important material, is the wood for each of the wheel's buckets. No doubt they originally used elm as this apparently copes well with the wet but isn't so good if you allow it to keep drying out. Sadly, elm is not as plentiful as it was 100 years ago but unbelievably George, the owner of a wonderful timber yard in Carmarthenshire, recently found a tree in the middle of his wood. It was just big enough to supply wood for all the buckets, so he's now cut it up and is seasoning the planks over the winter.

  Elm log (centre) ready to go!

Elm log in the sawmill

The existing leat (mill race) was pretty silted up but, because it lies along a spring-line and because it collects extensive run-off from the local hills, it has retained a flow despite 50 years of neglect. The primary flow was originally tapped off from the Brandybrook river about 600m upstream. Unfortunately, about half of this now crosses a neighbour's land and is no longer accessible to the Mill. Also, the weir has completely disappeared. However, with the springs and run-off there is enough residual flow to generate up to about 1.5kW (~2hp), at least during the winter months . To reduce maintenance in one difficult-to-get-at-section we are ducting the water through a culvert.

New sluice gates have been made by Kevin Harrison at his engineering company (Stowfledge) near Loughborough and we've started their installation in the leat.

 First sluice gate in position

Actually, none of the above tasks is as straightforward as it sounds so, realistically, it will be late Spring at the earliest before the grand re-opening of Roch Water Wheel.

After that we want to try and harness the power to drive a ground-source heat pump that will supply our underfloor heating in the house. But that's another project, possibly next year's, but don't hold your breath!

In removing the old wheel we fully exposed the end wall of the mill, which was is in serious need of re-pointing. After hundreds of years of getting pretty wet it is not surprising I suppose, but it's a job I could have done without. We have used traditional lime mortar for this, so that moisture can escape from the walls and also to help absorb the stresses and vibrations when the wheel is turning again.

At the beginning of April another engineering friend, Terry, very kindly came along to cut the old axle in two. The cut was made hard up against the pit wheel so that I can drill out the old iron wedges and release the remaining axle stub. Once that's done I can set about rebuilding the bearing supports and aligning the bearings.

Terry using an angle grinder to cut through the 150 yr old 4inch axle

Success. Now to drill out the wedges!