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7.30.2011

DeKalb High School Tower Clock Installation - 2

We staged all of the parts and materials in the future career center across the hall.  The school was very accommodating to the installation.  Without their assistance we wouldn't have been able to install the clock so quickly and efficiently.  We worked 12 to 14 hours a day for seven straight days.  It was great having all of the supplies so close.


 We created a small work area at the door into the tower.  This is where we did all of the custom fabrication required for a tower clock like this. 

Our drill press and other tools,  The door to the clock tower is at the left edge of this image.

Our work tables

The proper caption..."What are we thinking?"

DeKalb High School Tower Clock Installation - 1

Getting ready to reopen the create

A quick peek.
(07.30.11) We shipped it freight for insurance purposes so there was a bit of added anxiety to see how well the movement had traveled.  Of course it traveled just fine, the crate was built by an architect. :)


It was in good shape.

7.23.2011

Boxing It Up for Shipment

We wanted to ensure the safest possible shipment back to DeKalb. After removing all of the fragile or vulnerable parts we bolted the clock to the pallet and built the crate around it.
The clock was shipped July 25th 2011.

http://www.ttclock.com/

6.13.2011

DeKalb High School Tower Clock - Running Strong!

Right now we are running the clock using very little weight. We can do this now because the clock isn't really doing any work...yet. We won't know how much it's going to take until the final installation and the clock is under the actual working load. We are expecting to use two to three times more weight for the installation.


This clock was built to run with a second and a half swing. It is keeping pretty good time now but again until the clock is working under the planned load I'm sure we will have to do some adjustments to get it to keep good time.






www.ttclock.com

6.05.2011

DeKalb Tower Clock- Final Assembly

After nearly nine months of restoration the clock is back in one piece.




Bolted down atop its new stand. It's so tall we needed to remove some of the wood plank to make room for it up in the rafters. There is room enough for the pendulum to swing freely and weights to fall within the frame work. The ornament on the frame work are elements of prairie style design which were also evident in the architecture of the new high school.






6.02.2011

DeKalb High School Tower Clock - Minnesota Clock Makers Guild


(06.02.11) The Minnesota Clockmakers Guild made a visit. About a dozen of their members held one of their scheduled meeting at the shop to see the progress that had been made. The guild was instrumental in helping to determine the proper procedure in restoring this clock. Special thanks to the Minnesota Clockmaker Guild for their expertise and advise.



Refinishing - The DeKalb Tower Clock



This video shows a few of the steps that were used to refinish one of the larger brass wheels on the clock. After some experimenting with some different techniques, we found the way shown to create a very nice consistent finish. We built a turntable to work with our lathe, this would come in handy when it came to painting the inside faces of the wheel.






www.ttclock.com


4.23.2011

DeKalb Tower Clock Dial

The Dial weighs about 65 pounds and will be hung from the glass in the new school's clock tower. This shows the condition of the dial as it was found.  Where the two numerals are broken and missing.  Adjacent to the missing numerals there is a definite flat spot at the outside edge of the dial.   This was likely the cause of the damage.  Our guess is that the dial fell and hit a floor surface.  The fall would have put excessive force on the numerals causing them to break.

The clock was cleaned up a bit and replacement numerals we incorporated.

The dial was then sand blasted to remove all of the rust and corrosion.
The dial was then painted and clear coated.  What is amazing to me is the pride and respect that everyone has had who have helped along the way.  For instance all of the painting of the larger pieces were done outside of our shop.  They love to tell us of the great care they took in doing the work.  Some have even thanked us for letting them get involved.  I think that this is all evident in the results.

4.13.2011

DeKalb Tower Clock - Frame

The freshly painted clock frame (E. Howard green trimmed out in gold).
As part of the prep work for reassembly, the paint will be removed at all of the bushing locations along with all of the uniquely threaded bolt locations. 

3.24.2011

More Cleaning and Polishing

Here is another sequence of pictures that show the different steps of the restoration process.
Escapement wheel assembly before it was taken off the movement.
After the rust was removed and before polishing.
Ready for paint and lacquer.

3.16.2011

Dekalb Clock Tower History and Design

Installing a nearly 110 year old tower clock into an new tower requires consideration of not just the pragmatic but also the historical.  It is not just a clock in a tower. The tower where the DeKalb clock was originally, then the tower where it had be stored and the tower where it will run again are three different type spaces.   The nature of the tower changes how we perceive the clock. 

1902 DeKalb High School
The story of this clock begins at the site of the 1902 DeKalb High School.  During its time atop the school the clock was recognized by the 42" dial and the sound of its bell.   Located at the center of the main entry it was the main piece of the iconic elevation of the school.  Over time the bell portion of the tower was condemned for what was most likely water damage.  We have found evidence on the movement that water was getting into the room where it was stored as well. The base of pendulum is showing a considerable amount of rot and the bolt that holds the weight is showing decay as well.  There must have been a water source that would have caused water to run down the pendulum and into that connection.  In 1966 the bell was separated from the clock and moved to the front of the high school.  A new ritual began, the clock bell became a victory bell and to this day it is rung in recognition of team and individual student success. 


1974 Clinton Rosette Middle School
 The clock remained in the 1902 school until the building was removed in 1974. Clinton Rosette Middle school was constructed on the site of the 1902 building.  The clock was then stored ironical in the clock tower of the middle school.  It would then only live in the memory of the DeKalb community. 

In 2008 Scott Williams, who was then science teacher at DHS, brought three photograph slides to the new DeKalb High School design team.  The slides were images of the this clock and some of it's parts just after it was put in storage at the middle school.  He told us that the school district had held on to this piece of history and did not want to see it get lost and forgotten about. 


2011 clock tower -This picture was
 taken from the commons side
 looking back toward the main entry.
 The decision was to make it once again the focus of the High School's main entry.  The design requires the movement to be lowered from the dial elevation to the main floor level where it can be viewed from all sides.  The we will be able to get closer to the clock than ever before.  We will see the wheels turn, the weights drop and the fly spin when the bell rings. For the first time the clock will move from an exterior clock tower to an interior clock tower.  This decision will help preserve the clock for future generations.  The climate controlled tower will minimize wear and corrosion on the parts.  The dial and hands will be protected from the suns light, rain, sleet and snow. The original bell will be relocated to the new high school and maintain its use as a victory bell. A smaller bell will be incorporated for the clock to ring.

The relationship between the clock, tower, dial and school infuses the history and culture  The incorporation of the clock in the new high school will provide a powerful link between the past of Dekalb with the future of DeKalb.

2.21.2011

DeKalb Tower Clock - A New Home

The conceptual image of the clock tower at the main entry.  The administration office is to the right and the guidance office and career center is to the left.  The commons/ cafeteria is on the other side of the clock tower.  The clerestory windows bring in warm natural light.  The deep window sills protect the entry way from the suns direct rays.
The tower ready for window frames and glass.

2.15.2011

DeKalb Tower Clock - Cleaning and Polishing


We tested many rust remover chemical solutions and found a product that dissolves the rust without damaging the metal.
Removing the rust one piece at a time and tracking them with their part numbers.
After the rust has been removed it is time for polishing.  We use a lathe, a very fine file, three different grits of sand paper and a 3M radial bristle disc (1 micron) to bring back the shine. 

 
 Before and After

DeKalb Tower Clock - A Pile of Parts

Parts logged and waiting for attention.
Bagged and tagged.


DeKalb Tower Clock - Documenting the Parts

As the parts come off the movement we carefully document where each part came from.
Each part is given a part number and located on the images.
The parts with their new part number are logged into a spread sheet that helps us to track the cleaning, repair and sometimes replacement.
http://ttclock.com/

DeKalb Tower Clock - Dissassembly

...and so it begins.
Taking the frame apart.
Ready for a paint job.
http://ttclock.com/