CLASSIC BOAT MUSEUM
1. The original instalation in the lighthouse sat on a bed of mercury.
We needed to ensure a solid base was provided for in the museum setting, thus a framework of 100mm, (4"), box steel was made.
The photo shows a trial fit before the final location build.
2. The final installation site next to the lifeboat, "Jessie Lumb", and the first two lower sections fitted to the base.
3. All four bottom sections are now fitted and loosly bolted together.
4. The next pieces to be fitted are the four round lenses.
To give a perspective each lens in 1.2 metre, (4 ft).
Although the lens looks like five pieces of glass there are actually 31 separate pieces of glass.
The round lens is the main projector of the light.
5. Pieces of 18mm ply were cut to fit in the top quadrant of the lens, these would then be clamped together and the lens could be lifted.
6. The round lens being a heavy unit and the need to lift it 2.7 metres, (9ft), a lifting jig was constructed.
This fits under the inside ring of the lens and needed to clear the lower sections of the already constructed lens.
The jig then clamps the lens in between the two sides of the lens.
7. The lens on it's first test lift using the gantry.
8. The first lens being fitted to the bottom section.
The lens is fitted from the outside as there is a bevel face on the inside.
9. The first side fitted.
Each section needs to be millimeter perfect to fit as the holes and threaded pieces fit together.
10. Now we know what we are doing the second lens is fitted.
11. The remaining lenses are fitted.
12. Attention now turns to the top eight sections.
The height we are working at is now 2.4m.
13. Although these sections are smaller they are non the less heavy, added to which we bolted two together to be able to lift them easier.
As can be seen we made another jig to enable a safe lift.
14. The first two corners are fitted, four sections of the lens.
15. The third corner fitted, only one more lift to go.
16. You may be wondering at this point, how did we know how this all fits together?
We did not realise at the beginning that each section has a number stamp at the intersection of each corner.
You can see in the photo above this intersection is number 9.
The four main faces with the round lens are marked 3, 6, 9 & 12 representing the four quarters of a clock face.
We can only assume that each piece was made and crafted for it's particular place in the construction and are not interchangable.
17. One final piece fitted is a ring around the top to hold everything in place and ensure symmetry of the lenses below it.
18. The lens build is completed with a skirt around the base.
19. With the addition of a light the lens is complete.