“To put a positive spin on it, we’re considering it “a blessing in disguise”. That’s how Danish Windmill Manager Lisa Steen Riggs described getting the news that there was significant wood rot in the sheer beams of the Mill’s cap frame.  Just ten days ago, the reconstruction phase of the Mill’s major restoration project began with historic millwright, Ben Hassett, returning to Elk Horn to install the new wind shaft and brake wheel on the 1848 Danish Windmill. Over the next several days, the turret and cap frame were to be re-roofed while Hassett returned to his Kentucky workshop to bring back the new 67’ long new sails for the Mill.

The horizontal beams are apart of the cap frame that supports the Cap. The black and white picture is of the cap frame from 40 years ago.

Unfortunately, during the roof replacement, once the sheathing and flashing was removed, significant deterioration was discovered in the principal structural members of the cap frame, known as sheers. The sheer beams run from the front of the Mill supporting the weather beam (which carries the weight of the sails and gearing), to the rear of the Mill where the sheers extend outside and support the wind shaft and drive train.

Because they carry the entirety of the weight of the sails, fantail and roof structure, the severity of the deterioration will involve the removal of the cap from the structure. “During the initial inspection, I thought that the areas could be epoxy consolidated and structural steel added to help reinforce the damaged areas,” said millwright Hassett. “Upon implementation of the repairs, it became obvious that the rot in the beams is significantly more extensive than initially thought. As the decayed sections were removed, more than 50% of the beams are missing at the critical load bearing areas. Unfortunately the intended repairs were not possible, as there was not enough area and section of beam left to reinforce and we’ll need to remove the cap from the structure.”

“Given the age and complexity of the Windmill, we anticipated there could be some unexpected complications such as this,” said Riggs. “It’s disappointing that the sails won’t be up for Tivoli Fest this weekend, but we are so fortunate that the structural damage was uncovered during the re-roofing before the new sails were installed.”  The old cap frame will be removed once replacement timbers have been located. After the structural integrity of the cap is restored, the new wings will be installed. The Mill is launching a financial appeal for this new phase of the restoration project and welcomes tax deductible donations of any amount. The Mill is a 501(c)(3) non-profit organization.

(Press Release)