David Hulse – one of the pre-eminent model makers.

David Hulse

David Hulse is one of the pre-eminent model makers of the age. We are very fortunate that David has decided to donate his entire collection of working models to Dartmouth Museum, where they can be enjoyed by everybody and will be a resource for future generations.,

His Story

David Hulse was born in 1939 in Stoke-on-Trent. His father was a self-employed bootmaker and cobbler. But in 1947 the family moved to a small dairy farm on the North Staffordshire Moors, and it was here that David grew up and developed his twin passions for the natural world and for all things mechanical.

Life was extremely simple in the moorland communities in those days: ‘There was no mains water, no electric supply and the nearest telephone was a public box one mile away’, as David tells it. But for a boy growing up, it was ‘simply paradise.’

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Map of Staffordshire

Malbon House Farm was where he lived as a boy and Onecote is where he went to school.

Sheep in Tommy’s derelict Cottage he lived on Butterton Moor near to Malbon House Farm. Tommy helped on our farm at harvest time.

At first, the Hulse’s couldn’t afford a tractor and farmed their land with a beloved carthorse, ‘Fanny’, but in 1949 they purchased their first tractor and by the age of eleven David was taking his first lessons at the wheel of a Fordson Major E27N.

 My first driving lesson at the age of eleven.

Because the land had never been intensively farmed, the farm itself and the surrounding moorlands were rich in wildlife of every kind. David became a skilled photographer and at the age of 25, designed the radio-controlled camera with which many of his photos were taken.

The remote control focused on the swallow’s nest

The photograph below was taken in the spring of 1965.

APPRENTICESHIP

In 1955 David left school and his carefree life on the farm to begin an engineering apprenticeship at Thomas Bolton and Sons, a famous copper and brass manufacturers, near Cheadle in Staffordshire. This was not only the beginning of David’s career in industry, but his journey to work involved him in what was to become another lifelong passion: motorbikes!

David’s First Motorbike.

David’s apprenticeship gave him a good grounding in manufacturing engineering, and he learned to use a wide variety of machine tools.

On his 17th birthday he was given an old centre lathe made by the Vernon Machine Co. of Massachusetts. This lathe, which is now over 125 years old, was to become his pride and joy. It is the machine on which all his historical models have been made and is still in use in his workshop today.

At the end of his 5-year apprenticeship David graduated to the drawing office. Here he acquired further skills that would prove invaluable to him, both in his career and in creating the detailed working drawings for his models from scratch.

The Vernon Lathe.

ADVENTURES ABROAD

Over the next seven years, during his holidays from work, David had many adventures abroad on his motorcycles – travelling on either a 350cc KSS Velocette or the more powerful 500cc BSA Gold Star he purchased in 1958. You can read about these adventures in David’s entertaining book ‘In My Lifetime’. Suffice it to say that David has covered over 250,000 miles on his various motorbikes and still has four in his workshop!

Waiting beside a Log Cabin in Southern Yugoslavia

THE POTTERIES

By 1966 David was working for a specialist company designing machines for the pottery industry and the demands of work put an end to his extended travels.

A further inducement to settle down occurred when he met Julie, a local primary school teacher, whom he married in 1969. Julie, who shared her husband’s passion for Industrial Archaeology, was to be a constant support in his work and in the research for his models.

In 1973 the company David worked for was taken over by Royal Doulton and David became Chief Development Engineer for this group of thirteen companies. During his career David oversaw an exciting period of innovation in the pottery industry: he is the holder of no less than seventeen patents! One of the techniques which he helped to introduce in this country was the production of fine table ware by pressing dry powdered clay, using powerful hydraulic presses. This method would later prove invaluable in producing the tens of thousands of tiny bricks required for his historic engine models.

Wedding Photo at St Michael’s Church
Rocester in Staffordshire. April 1969.

The Brick-making Machine.

A close-up of press after producing four clay bricks ready for firing!

REINVENTING THE AGE OF STEAM

It was around this time that David first considered what was to become his lifetime project: recreating in miniature some of the most significant steam engines of the 18th century. These early engines were incorporated into the brick buildings which housed them, and he realised that -with his wealth of experience as an engineer in the ceramics industry – he was uniquely equipped to meet the challenge.

To achieve this aim, he designed and constructed the world’s only miniature brick-making machine, employing the same technology which he had pioneered at Royal Doulton. The miniature bricks are fired at a temperature of 1050oC in the same atmospheric conditions which would have been used three hundred years ago. Consequently, they show all the varied colours found in building bricks of the period. But David’s attention to detail is not confined to bricks: every small metal component – down to the smallest rivet – has been hand forged or fabricated and all the wood is hand sawn and adzed from fine-grained Japanese oak – to preserve the illusion of scale.

Underlying this extraordinary craftsmanship is over fifty years of research. None of these early engines remains in its original state and very little documentary evidence has survived to describe their detailed working and construction. With the help of his late wife Julie, David combed the archives for drawings and letters and examined original engines in museums. He also drew on the work of other enthusiasts and leading experts in the field. Above all, he applied his deep understanding of ‘how things work’ and practical problem solving to create the most detailed and faithful models possible.

These models have rightly won several national awards and have been seen on television and exhibited at many museums and galleries in the Midlands. We are delighted that they have now found a permanent home in Dartmouth – the birthplace of Thomas Newcomen!

David would like to dedicate this exhibition to his daughter Natasha and Jenny his soul mate for giving him all the time and encouragement needed to bring the research together and complete these engines in miniature.

 

David Hulse

Staffordshire miniature engine collection given permanent new home.

Published 1 August 2023
By Bob Hockenhull
Reporter, Midlands Today

 

A retired engineer, who has spent more than 50 years building miniature models of engines from the industrial revolution, has said he is “sad and pleased” they are to be given a permanent home.

Each of the eight models has taken David Hulse about 6,000 hours to complete. They contain thousands of miniature bricks the 84-year-old, from Stone, Staffordshire, fashioned by hand.  The collection is to be permanently housed at a site in Dartmouth in Devon.

Mr Hulse, a former engineer at Royal Doulton group of potteries, said the 18th Century atmospheric engines paved the way for the industrial revolution in Britain and throughout the world.

This model is a miniature of the original atmospheric
engine designed by Thomas Newcomen in 1712.

The overhead rocking beam of Thomas Newcomen’s 1712 engine.

The models are to be given a permanent home at a museum in Dartmouth, Devon.

The eight models currently on display at his home are a 16th of the size of the originals and contain more than 190,000 bricks.

“I’ve done all the research, all the drawings and all the materials have been processed and made by me,” he said.

      “Every one of them is made from what it would have been made from in the 18th Century.”

The collection includes the original atmospheric engine designed by Thomas Newcomen, to pump water out of a Dudley coal mine in south Staffordshire. The invention allowed miners to extract previously inaccessible coal without the fear of flooding.

     David Hulse took about 6,000 hours to complete each model.

Next month, (August 2023) the collection will be moved to a museum in Dartmouth, the town where Thomas Newcomen was born in 1663.

“I feel sad and pleased all in the same sentence,” said Mr Hulse.

“I wanted a substantial place where they could be viewed by everyone,” he added.

David Hulse’s meticulous craftsmanship in constructing his miniature steam engine models is nothing short of awe-inspiring. Let’s delve into the steps he took to bring these mechanical marvels to life:

  • Research and Study:
    • Hulse began by immersing himself in historical records, technical drawings, and literature related to the original steam engines.
    • Understanding the intricacies of each engine’s design, function, and operation was crucial. He studied the works of engineers like Thomas Newcomen, James Watt, and others.
  • Scale Modelling:
    • Hulse decided on the scale for his models. Choosing an appropriate scale allows for accuracy while ensuring the final model remains manageable.
    • He opted for a common scale, such as 1:16 and 1:10, to maintain consistency across his collection.
  • Materials Selection:
    • Selecting the right materials was vital, he used a combination of brass, steel, copper, and other metals.
    • For the intricate components, he used jeweller’s saws, files, and precision tools.

Dartmouth Museum on Butterwalk Devon
is within this Grade One Listed building
dated 1640.

4 Component Fabrication:

  • Each component—whether it was a piston, cylinder, valve, or connecting rod—required meticulous craftsmanship.
  • Hulse shaped and polished these parts to their exact specifications.
  • His attention to detail ensured that even the tiniest bolts and nuts were faithfully replicated.

5  Assembly and Fitment:

  • Assembling the components was like solving a complex puzzle. Hulse carefully fitted each piece together.
  • Achieving smooth movement of pistons and crankshafts was essential. He used miniature bearings or bushings.

6 Boiler and Steam System:

  • The boiler, which generated steam, was a critical part, he crafted it with precision.
  • Ensuring proper steam flow, pressure, and safety features required expertise.
  • Tiny pipes, valves, and regulators would have been meticulously installed.

7  Finishing Touches:

Hulse’s models weren’t just functional; they are also works of art. He would have added details like rivets, gauges, and control levers. The engines’ housings—often resembling miniature buildings—were constructed with incredible patience. Each brick, window, and door were carefully placed.

    8 Testing and Refinement:

    Hulse tested each model rigorously. Adjustments were made to optimize performance. Achieving smooth motion, realistic sound, and accurate timing was part of the refinement process.

     9  Display and Documentation:

    Once complete, he proudly displayed his models. Their intricate details captivated viewers. He documented the construction process, sharing insights with fellow enthusiasts.

    10  Legacy and Inspiration:

    Hulse’s dedication to preserving engineering history through these models serves as an inspiration to future generations. His work reminds us of the brilliance and innovation that shaped our world.

    In summary, David Hulse’s models are a testament to both engineering precision and artistic passion—a fusion of science and craftsmanship that celebrates the ingenuity of the past.

     

    The David Hulse Collection of Model Steam Engines

    Dartmouth Museum is honoured to have been chosen to house a permanent exhibition of David Hulse’s world-renowned collection of miniature atmospheric steam engines: engines that initiated the industrial revolution and changed the world.

    David Hulse is one of the pre-eminent model makers of our time. After an apprenticeship in engineering, he rose to be Chief Development Engineer at the Royal Doulton Group of companies and holds seventeen patents for machines used in the pottery industry.

    In 1974, using the skills he had acquired as an engineer in the ceramics industry, he was determined to construct in miniature what he considered to be the most important steam engines of the 18th Century. The result is a collection of working models of unparalleled accuracy and detail, which have won many awards and been exhibited in museums and exhibitions throughout the UK.

    David chose 7 engines to build in addition to Newcomen’s, each of which made a significant advance in efficiency or effectiveness. However, for almost 70 years Newcomen’s engine was the standard, and it was only in 1779, that James Watt created a breakthrough in terms of power and coal consumption, while 25 years later, the Cornishman engineer Richard Trevithick’s engine in 1804, was small and light enough to be applied to transport, notably trains and ships.

    David has spent 50 years building working models of the engines that powered Britain’s industrial revolution. David Hulse made every component of the models himself, to a 1/16th scale, including the bricks of the houses for each engine 191,000 bricks in all, and taking on average 6,000 to research, design and build every model. Until now they were displayed at his house, in Stone, Staffordshire, but Daivd Hulse had long been interested in finding a space in which to exhibit these machines and Dartmouth was an obvious choice given its association with Thomas Newcomen.

    The eight model engines travelled down from David’s home last week and arrived in Dartmouth on Tuesday, (7th August 2024) and on Wednesday, the engines were packed into a specially designed case and lifted into the 400-year-old building by crane.

    The team at Dartmouth Museum are expecting visitors from around the world are expected to visit Dartmouth to study them and have already received enquiries from Japan. These engines are the foundation of Dartmouth Museum’s two new exhibitions that tell the story of the atmospheric steam engines that changed the world and their impact on Dartmouth and the lives of its people.

    The exhibition opened in October. You can see a video of David talking about his engines in the film ‘Mechanical Wonders’. www, davidhulse.co.uk.

    For enquiries, please contact Jonathan Turner. Tel: 07887 948617 Email: JonathanTurner.1@outlook.co

    The Newcomen Society and David Hulse share a fascinating connection related to the engines that powered Britain’s industrial revolution. Let’s delve into their stories:

    1.  Newcomen Society:

      • The Newcomen Society is an organization dedicated to the study and preservation of the history of engineering and technology. It takes its name from Thomas Newcomen, an English inventor and engineer.
      • Thomas Newcomen is renowned for inventing the atmospheric steam engine in the early 18th century. His engine played a pivotal role in the industrial revolution by enabling efficient water pumping from mines.
      • The Newcomen Society collaborates with enthusiasts, researchers, and historians to explore and celebrate the legacy of early engineering achievements.

    2.  David Hulse:

      • David Hulse, a pre-eminent model maker, has spent over 50 years meticulously constructing working models of the engines that drove Britain’s industrial revolution.
      • After an engineering apprenticeship, Hulse rose to become the Chief Development Engineer at the Royal Doulton Group. He holds 17 patents for machines used in the pottery industry.
      • In 1974, inspired by his engineering background, he embarked on a remarkable project: he decided to create miniature working models of the most significant steam engines of the 18th century.
      • His collection includes engines beyond Newcomen’s, each representing a significant advancement in efficiency or effectiveness.
      • Hulse’s models are built to a 1/16th scale and exhibit unparalleled accuracy and detail. They have won numerous awards and have been exhibited in museums across the UK.
      • Notably, Hulse’s collection features the original atmospheric engine designed by Thomas Newcomen, which revolutionized coal mining by allowing miners to extract previously inaccessible coal.

    3.  Dartmouth Museum:

        • Dartmouth Museum, located in Dartmouth, South Devon, has been chosen to house a permanent exhibition of David Hulse’s world-renowned collection of miniature atmospheric steam engines.
        • The collection includes the atmospheric engine by Newcomen, as well as models of engines by other pioneers like James Watt, James Pickard, Matthew Wasborough, Francis Thompson, and Richard Trevithick.

     

    How did David Hulse get interested in model making?

    David Hulse’s fascination with model making sprouted from a blend of curiosity, engineering passion, and an unwavering love for precision. Let’s delve into the origins of his captivating journey:

    1. Engineering Roots:
      • David Hulse began his professional life as an engineering apprentice. His early exposure to mechanical systems, intricate designs, and problem-solving ignited a spark within him.
      • The world of engineering, with its gears, levers, and mechanisms, became a canvas for his creativity.
    2. Chief Development Engineer:
      • Hulse’s career trajectory led him to become the Chief Development Engineer at the Royal Doulton Group.
      • His work involved designing and improving machines used in the pottery industry. This role allowed him to hone his engineering skills and deepen his understanding of precision engineering.
    3. The Miniature Quest:
      • In 1974, David Hulse embarked on an extraordinary mission: to create miniature working models of historic steam engines.
      • His motivation was twofold: a desire to celebrate the engineering marvels of the past and a personal challenge to replicate their intricate workings on a smaller scale.

     

    1. Meticulous Craftsmanship:
      • Armed with meticulous attention to detail, Hulse meticulously crafted each model to a 1/16th scale.
      • His models weren’t mere replicas; they were functional, capturing the essence of the original engines.
      • The process involved studying historical documents, analysing blueprints, and painstakingly assembling every component.
    2. The Newcomen Connection:
      • Among Hulse’s remarkable collection, one engine stands out: the atmospheric engine designed by Thomas Newcomen.
      • Newcomen’s engine revolutionized coal mining by efficiently pumping water from mines. Hulse’s model pays homage to this pivotal invention.
    3. Awards and Recognition:
      • Hulse’s models garnered acclaim. Their precision and authenticity earned him numerous awards.
      • Museums across the UK showcased his work, allowing visitors to marvel at the intricate gears, pistons, and flywheels.
    4. Legacy and Inspiration:
      • David Hulse’s passion for model making transcends craftsmanship. It’s a testament to the ingenuity that shaped our industrial history.
      • His models inspire future engineers, reminding them of the power of imagination and the beauty of mechanical artistry.

    In summary, David Hulse’s interest in model making sprang from a blend of technical expertise, historical reverence, and an unwavering commitment to precision. His miniature engines continue to captivate enthusiasts and ignite curiosity about the machines that transformed our world.