The Hills and the Vale

by Richard Jefferies

And much, if not all, of this marvellous transformation, of this abounding life and vigorous vitality, is due to the energy and the forethought, the will of one man. It is notorious that the Swindon of to-day is the creation of the companion of Brunel at the lunch in the furze-bushes. Sir Daniel Gooch has had a wonderful life. Beginning literally at the beginning, he rose from stage to stage, till he became the responsible head of the vast company in whose service he had commenced life. In that position he did not forget the place where his early years were passed, but used his influence to enrich it with the real secret of wealth, employment for the people. In so doing, time has proved that he acted for the best interests of the company, for, apart from monetary matters, the mass of workmen assembled at this spot are possessed of overwhelming political power, and can return the man they choose to Parliament. Thus the company secures a representative in the House of Commons.

Among the institutions which the railway company fostered was the primitive reading-room which has been alluded to. Under their care this grew and grew, until it became a Mechanics' Institute, or, rather, a department of science and art, which at the present day has an intimate connection with South Kensington. Some hundred prizes are here annually distributed to the numerous students, both male and female, who can here obtain the very best instruction, at the very smallest cost, in almost every branch of learning, from sewing to shorthand, from freehand drawing to algebra and conic sections. On one occasion, while distributing the prizes to the successful competitors, Sir Daniel Gooch laid bare some of his early struggles as an incentive to the youth around him. He admitted that there was a time, and a dark hour, when he all but gave up hopes of ultimate success, when it seemed that the dearest wish of his heart must for ever go without fulfilment. In this desponding mood he was slowly crossing a bridge in London, when he observed an inscription upon the parapet—Nil Desperandum (Never despair). How he took heart at this as an omen, and went forth and persevered till——The speaker did not complete the sentence, but all the world knows what ultimately happened, and remembers the man who laid the first Atlantic cable. The great lesson of perseverance, of patience, was never drawn with better effect.

In the Eastern tales of magicians one reads of a town being found one day where there was nothing but sand the day before. Here the fable is fact, and the potent magician is Steam. Here is, perhaps, the greatest temple that has ever been built to that great god of our day. Taking little note of its immense extent, of the vast walls which enclose it, like some fortress, of the tunnel which gives entrance, and through which three thousand workmen pass four times a day, let us enter at once and go straight to the manufacture of those wheels and tires and axles of which we have heard so much since the tragedy at Shipton. To look at a carriage-wheel, the iron carriage-wheel, one would imagine that it was all one piece, that it was stamped out at a blow, so little sign is there of a junction of parts. The very contrary is the fact: the wheel is made of a large number of pieces of iron welded together, and again and again welded together, till at last it forms one solid homogeneous mass. The first of these processes consists in the manufacture of the spokes, which are made out of fine iron. The spoke is made in two pieces, at two different forges, and by two distinct gangs of men. A third forge and a third gang are constantly employed in welding these two detached parts in one continuous piece, forming a spoke. One of these parts resembles a T with the downward stroke very short, and the cross stroke at the top slightly bent, so as to form a section of a curve. The other piece is about the same length, but rather thicker, and at its larger end somewhat wedge-shaped. This last piece forms that part of the spoke which goes nearest to the centre of the wheel. These two parts, when completed, are again heated to a red heat, and in that ductile state hammered with dexterous blows into one, which then resembles the same letter T, only with the downward stroke disproportionately long. Eight or more of these spokes, according to the size of the wheel, and whether it is intended for a carriage, an engine, or tender, are then arranged together on the ground, so that the wedge-shaped ends fit close together, and in that position are firmly fixed by the imposition above them of what is called a 'washer,' a flat circular piece of iron, which is laid red-hot on the centre of the embryo wheel, and there hammered into cohesion. The wheel is then turned over, and a second 'washer' beaten on, so that the partially molten metal runs, and joins together with the particles of the spokes, and the whole is one mass. In the ordinary cart-wheel or gig-wheel the spokes are placed in mortise-holes made in a solid central block; but in this wheel before us, the ends of the spokes, well cemented together by the two washers, form the central block or boss. The ends of the spokes do not quite touch each other, and so a small circular space is left which is subsequently bored to fit the axle. The wheel now presents a curiously incomplete appearance, for the top strokes of the T's do not touch each other. There is a space between each, and these spaces have now to be filled with pieces of red-hot iron well welded and hammered together. To the uninitiated it would seem that all this work is superfluous; that the wheel might be made much more quickly in two or three pieces, instead of all these, and that it would be stronger. But the practical men engaged in the work say differently. It is their maxim that the more iron is hammered, the stronger and better it becomes; therefore all this welding adds to the strength of the wheel. In practice it is found quicker and more convenient to thus divide the labour than to endeavour to form the wheel of fewer component parts. The wheel is now taken to the lathe, and a portion is cut away from its edge, till a groove is left so as to dovetail into the tyre.

The tyres, which are of steel, are not made here; they come ready to be placed upon the wheel, and some care has to be taken in moving them, for, although several inches in thickness and of enormous strength, it has occasionally happened that a sudden jar from other solid bodies has fractured them. One outer edge of the tyre is prolonged, so to say, and forms the projecting flange which holds the rails and prevents the carriage from running off the road. So important a part requires the best metal and the most careful manufacture, and accordingly no trouble or expense is spared to secure suitable tyres. One of the inner edges of the tyre, on the opposite side to the flange, is grooved, and this groove is intended to receive the edge of the wheel itself; they dovetail together here. The tyre is now made hot, and the result of that heating is an expansion of the metal, so that the circle of the tyre becomes larger. The wheel is then driven into the tyre, which fits round it like a band. As it grows cool the steel tyre clasps the iron wheel with enormous force, and the softer metal is driven into the groove of the steel. But this is not all. The wheel is turned over, and the iron wheel is seen to be some little distance sunk, as it were, beneath the surface of the tyre. Immediately on a level with the iron wheel there runs round the steel tyre another deeper groove. The wheel is again heated—not to redness, for the steel will not bear blows if too hot—and when the tyre is sufficiently warm, a long, thin strip of iron is driven into this groove, and so shuts the iron wheel into the tyre as with a continuous wedge. Yet another process has to follow—yet another safeguard against accident. The tyre, once more heated, is attacked with the blows of three heavy sledge-hammers, wielded by as many stalwart smiths, and its inner edge, by their well-directed blows, bent down over the narrow band of iron, or continuous wedge, so that this wedge is closed in by what may be called a continuous rivet. The wheel is now complete, so far as its body is concerned, and to look at, it seems very nearly impossible that any wear or tear, or jar or accident, could disconnect its parts—all welded, overlapped, dovetailed as they are. Practically it seems the perfection of safety; nor was it to a wheel of this character that the accident happened. The only apparent risk is that there may be some slight undiscovered flaw in the solid steel which, under the pressure of unforeseen circumstances, may give way. But the whole design of the wheel is to guard against the ill-effects that would follow the snapping of a tyre. Suppose a tyre to 'fly'—the result would be a small crack; supposing there were two cracks, or ten cracks, the speciality of this wheel is that not one of those pieces could come off—that the wheel would run as well and as safely with a tyre cracked through in a dozen places as when perfectly sound. The reason of this is that every single quarter of an inch of the tyre is fixed irremovably to the outer edge of the iron wheel, by the continuous dovetail, by the continuous wedge, and by the continuous overlapping. So that under no condition could any portion of the tyre fly off from the wheel. Close by this wheel thus finished upon this patent process there was an old riveted wheel which had been brought in to receive a new tyre on the new process. This old wheel aptly illustrates the advantages of the new one. Its tyre is fixed to the wheel by rivets or bolts placed at regular intervals. Now, the holes made for these bolts to some extent weaken both tyre and wheel. The bolt is liable, with constant shaking, to wear loose. The bolt only holds a very limited area of tyre to the wheel. If the tyre breaks in two places between the bolts, it comes off. If a bolt breaks, or the tyre breaks at the bolt, it flies. The tyre is, in fact, only fixed on in spots with intervals between. The new fastening leaves no intervals, and instead of spots is fixed everywhere. This is called the Gibson process, and was invented by an employé of the company. Latterly another process has partially come into vogue, particularly for wooden wheels, which are preferred sometimes on account of their noiselessness. By this (the Mansell) process, the tyres, which are similar, are fastened to the wheels by two circular bands which dovetail into the tyre, and are then bolted to the wood.

To return to the wheel—now really and substantially a wheel, but which has still to be turned so as to run perfectly true upon the metals—it is conveyed to the wheel lathe, and affixed to what looks like another wheel, which is set in motion by steam-power, and carries our wheel round with it. A workman sets a tool to plane its edge, which shaves off the steel as if it were wood, and reduces it to the prescribed scale. Then, when its centre has been bored to receive the axle, the genesis of the wheel is complete, and it enters upon its life of perpetual revolution. How little do the innumerable travellers who are carried to their destination upon it imagine the immense expenditure of care, skill, labour, and thought that has been expended before a perfect wheel was produced.

Next in natural order come the rails upon which the wheel must run. The former type of rail was a solid bar of iron, whose end presented a general resemblance to the letter T, which was thick at the top and at the bottom, and smaller in the middle. It was thought that this rail was not entirely satisfactory, for reasons that cannot be enumerated here, and accordingly a patent was taken out for a rail which, it is believed, can be more easily and cheaply manufactured, with a less expenditure of metal, and which can be more readily attached to the sleepers. In reality it is designed upon the principle of the arch, and the end of these rails somewhat resembles the Greek letter Ω, for they are hollow, and formed of a thin plate of metal rolled into this shape. Coming to this very abode of the Cyclops, the rail-mill, the first machine that appears resembles a pair of gigantic scissors, which are employed day and night in snipping off old rails and other pieces of iron into lengths suitable for the manufacture of new rails.

These scissors, or, perhaps, rather pincers, are driven by steam-power, and bite off the solid iron as if it were merely strips of ribbon. There is some danger in this process, for occasionally the metal breaks and flies, and men's hands are severely injured. At a guess, the lengths of iron for manufacture into rails may be about four feet long, and are piled up in flat pieces eight or nine inches or more in height. These pieces are carried to the furnace, heated to an intense heat, and then placed under the resistless blows of a steam-hammer, which welds them into one solid bar of iron, longer than the separate pieces were. The bar then goes back to the furnace, and again comes out white-hot. The swinging-shears seize it, and it is swung along to the rollers. These rollers are two massive cylindrical iron bars which revolve rapidly one over the other. The end of the white-hot metal is placed between these rollers, and is at once drawn out into a long strip of iron, much as a piece of dough is rolled out under the cook's rolling-pin. It is now perfectly flat, and entirely malleable. It is returned to the furnace, heated, brought back, and placed in a second pair of rollers. This second pair have projections upon them, which so impress the flat strip of iron that it is drawn out into the required shape. The rail passes twice through these rollers, once forwards, then backwards. Terrible is the heat in this fiery spot. The experienced workman who guides the long red-hot rails to the mouth of the rollers is protected with a mask, with iron-shod shoes, iron greaves on his legs, an iron apron, and, even further, with a shield of iron. The very floor beneath is formed of slabs of iron instead of slabs of stone, and the visitor very soon finds this iron floor too hot for his feet. The perfect rail, still red-hot or nearly, is run back to the circular saw, which cuts it off in regular lengths; for it is not possible to so apportion the iron in each bundle as to form absolutely identical strips. They are proportioned so as to be a little longer than required, and then sawn off to the exact length. While still hot, a workman files the sawn ends so that they may fit together closely when laid down on the sleepers. The completed rails are then stacked for removal on trucks to their destination. The rollers which turn out these rails in so regular and beautiful a manner are driven by a pair of engines of enormous power. The huge fly-wheel is twenty feet in diameter, and weighs, with its axle, thirty-five tons. When these rails were first manufactured, the rollers were driven direct from the axle of the fly-wheel, and the rails had to be lifted right over the roller—a difficult and dangerous process—and again inserted between them on the side at which it started. Since then an improvement has been effected, by which the rails are sent backwards through the rollers, thus avoiding the trouble of lifting them over. This is managed by reversing the motion of the rollers, which is done in an instant by means of a 'crab.'

Immediately adjacent to these rail-mills are the steam-hammers, whose blows shake the solid earth. The largest descends with the force of seventy tons, yet so delicate is the machinery that visitors are shown how the same ponderous mass of metal and the same irresistible might can be so gently administered as to crush the shell of a nut without injuring the kernel. These hammers are employed in beating huge masses of iron into cranks for engines, and other heavy work which is beyond the unaided strength of man. Each of the hammers has its own steam-boiler and its furnace close at hand, and overhead there are travelling cranes which convey the metal to and fro. These boilers may be called vertical, and with the structure on which they are supported have a dome-like shape. Hissing, with small puffs of white steam curling stealthily upwards, they resemble a group of volcanoes on the eve of an eruption. This place presents a wonderful and even terrible aspect at night, when the rail-mill and steam-hammers are in full swing. The open doors of the glaring furnaces shoot forth an insupportable beam of brilliant white light, and out from among the glowing fire comes a massive bar of iron, hotter, whiter than the fire itself—barely to be looked upon. It is dragged and swung along under the great hammer; Thor strikes, and the metal doubles up, and bends as if of plastic clay, and showers of sparks fly high and far. What looks like a long strip of solid flame is guided between the rollers, and flattened and shaped, till it comes out a dull-red-hot rail, and the sharp teeth of the circular saw cut through it, throwing out a circle of sparks. The vast fly-wheel whirls round endless shaftings, and drums are revolving overhead, and the ear is full of a ceaseless overpowering hum, varied at intervals with the sharp scraping, ringing sound of the saw. The great boilers hiss, the furnaces roar, all around there is a sense of an irresistible power, but just held in by bars and rivets, ready in a moment to rend all asunder. Masses of glowing iron are wheeled hither and thither in wheelbarrows; smaller blocks are slid along the iron floor. Here is a heap of red-hot scraps hissing. A sulphurous hot smell prevails, a burning wind, a fierce heat, now from this side, now from that, and ever and anon bright streaks of light flow out from the open furnace doors, casting grotesque shadows upon the roof and walls. The men have barely a human look, with the reflection of the fire upon them; mingling thus with flame and heat, toying with danger, handling, [as] it seems, red-hot metal with ease. The whole scene suggests the infernal regions. A mingled hiss and roar and thud fill the building with reverberation, and the glare of the flames rising above the chimneys throws a reflection upon the sky, which is visible miles away, like that of a conflagration.

Stepping out of this pandemonium, there are rows upon rows of gleaming forges, each with its appointed smiths, whose hammers rise and fall in rhythmic strokes, and who manufacture the minor portions of the incipient locomotive. Here is a machine the central part of which resembles a great corkscrew or spiral constantly revolving. A weight is affixed to its inclined plane, and is carried up to the required height by the revolution of the screw, to be let fall upon a piece of red-hot iron, which in that moment becomes a bolt, with its projecting head or cap. Though they do not properly belong to our subject, the great marine boilers in course of construction in the adjoining department cannot be overlooked, even if only for their size—vast cylinders of twelve feet diameter. Next comes the erecting shop, where the various parts of the locomotive are fitted together, and it is built up much as a ship from the keel. These semi-completed engines have a singularly helpless look—out of proportion, without limbs, and many mere skeletons. Close by is the department where engines out of repair are made good. Some American engineer started the idea of a railway thirty feet wide, an idea which in this place is partially realized. The engine to be repaired is run on to what may be described as a turn-table resting upon wheels, and this turn-table is bodily rolled along, like a truck, with the engine on it, to the place where tools and cranes and all the necessary gear are ready for the work upon it. Now by a yard, which seems one vast assemblage of wheels of all kinds—big wheels, little wheels, wheels of all sizes, nothing but wheels; past great mounds of iron, shapeless heaps of scrap, and then, perhaps, the most interesting shop of all, though the least capable of description, is entered. It is where the endless pieces of metal of which the locomotive is composed are filed and planed and smoothed into an accurate fit; an immense building, with shafting overhead and shafting below in endless revolution, yielding an incessant hum like the sound of armies of bees—a building which may be said to have a score of aisles, up which one may walk with machinery upon either side. Hundreds of lathes of every conceivable pattern are planing the solid steel and the solid iron as if it were wood, cutting off with each revolution a more or less thick slice of the hard metal, which curls up like a shaving of deal. So delicate is the touch of some of these tools, so good the metal they are employed to cut, that shavings are taken off three or more feet long, curled up like a spiral spring, and which may be wound round the hand like string. The interiors of the cylinders, the bearings, those portions of the engines which slide one upon the other, and require the most accurate fit, are here adjusted by unerring machinery, which turns out the work with an ease and exactness which the hand of man, delicate and wonderful organ as it is, cannot reach. From the smallest fitting up to the great engine cranks, the lathes smooth them all—reduce them to the precise size which they were intended to be by the draughtsman. These cranks and larger pieces of metal are conveyed to their lathes and placed in position by a steam crane, which glides along upon a single rail at the will of the driver, who rides on it, and which handles the massive metal almost with the same facility that an elephant would move a log of wood with his trunk. Most of us have an inherent idea that iron is exceedingly hard, but the ease with which it is cut and smoothed by these machines goes far to remove that impression.

The carriage department does not offer so much that will strike the eye, yet it is of the highest importance. To the uninitiated it is difficult to trace the connection between the various stages of the carriage, as it is progressively built up, and finally painted and gilded and fitted with cushions. Generally, the impression left from an inspection is that the frames of the carriages are made in a way calculated to secure great strength, the material being solid oak. The brake-vans especially are made strong. The carriages made here are for the narrow gauge, and are immensely superior in every way to the old broad-gauge carriage, being much more roomy, although not so wide. Over the department there lingers an odour of wood. It is common to speak of the scented woods of the East and the South, but even our English woods are not devoid of pleasant odour under the carpenter's hands. Hidden away amongst the piles of wood there is here a triumph of human ingenuity. It is an endless saw which revolves around two wheels, much in the same way as a band revolves around two drums. The wheels are perhaps three feet in diameter, and two inches in thickness at the circumference. They are placed—one as low as the workman's feet, another rather above his head—six or seven feet apart. Round the wheels there stretches an endless narrow band of blue steel, just as a ribbon might. This band of steel is very thin, and almost half an inch in width. Its edge towards the workman is serrated with sharp deep teeth. The wheels revolve by steam rapidly, and carry with them the saw, so that, instead of the old up and down motion, the teeth are continually running one way. The band of steel is so extremely flexible that it sustains the state of perpetual curve. There are stories in ancient chronicles of the wonderful swords of famous warriors made of such good steel that the blade could be bent till the point touched the hilt, and even till the blade was tied in a knot. These stories do not seem like fables before this endless saw, which does not bend once or twice, but is incessantly curved, and incessantly in the act of curving. A more beautiful machine cannot be imagined. Its chief use is to cut out the designs for cornices, and similar ornamental work in thin wood; but it is sufficiently strong to cut through a two-inch plank like paper. Every possible support that can be afforded by runners is given to the saw; still, with every aid, it is astonishing to see metal, which we have been taught to believe rigid, flexible as indiarubber. Adjoining are frame saws, working up and down by steam, and cutting half a dozen or more boards at the same time. It was in this department that the Queen's carriage was built at a great expenditure of skill and money—a carriage which is considered one of the masterpieces of this particular craft.