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I posted a project on making two windows for the restoration of the Delmar Caboose. The restoration committee asked our Mason - Dixon Woodworkers Club to make some of the items needed for the restoration of the caboose. I volunteered to make the items.

I posted the build of the windows


Now we are on to the building of a new door. The old door had had some vandals get friendly with it.


The door dimensions were 71" tall and 24" wide. Not the size that you would find at the big box stores.

The door stiles (sides) were made from popular and were 4 5/8" wide 1 3/8" thick.


I used a router set that I bought about 6-7 years ago figuring some day I'd use it. (See it worked out)

I first cut the ends of the rails with the matching router bits.


All of the rest of the door was made with pine.


They were all made with 2 X 8 to 2X 12 salvage materials less than 20" long that had been donated to the toy workshop.

Dry run of the door without the panels and the internal stiles.


The door panels were made with the same salvage wood. They were resawed into 3/4" thick slices and then planed to make them smooth. They ended up between 5/8 and 3/4" thick around 11/16" thick

I then cut the edging on both sides of the panels.


Gluing up with the panels and the internal rails in place.


The completed door.


Additional projects is the siding


Completion

Gallery

Comments

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Karson, Thanks for showing this. What a great project, way to keep the history alive for those to come later on.
 

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204 Posts
Hi Karson. Great job on the door, I like the way you show the work in progress. looks like you are giving your time to another worthy cause. Way to go!
 

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Karson,
That logo on the "crummy" brings back memories. My Dad worked at the roundhouse and the coal dock for the Pennsy. He later switched to the rip track and was a car knocker. He was hurt there and medicaled out. In the teens and '20's my Grand Dad was a blacksmith and worked on the wreck train for the Pennsylvania. This was all in Logansport, Indiana which at that time was a division. Fix'er up nice, those old Crummies saw a lot of use. Nice door.
Tom
 

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Nice post on the progress of making the door.
 

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Thanks guys. It was fun. My wife was after me to fix the screen door for the back screened porch. I didn't want to tell her I was making a door for a caboose and not make one for her. So I'm now working on her door.
 

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Good idea to keep the wife appeased once in awhile. Hey, this door looks real good. Are you going to reuse the door hardware as well?
 

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Hi Karson;

Good job on the door and the post.

Wives sure can be pesky huh? LOL

Lee
 

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Another worth while job well done and it was iteresting to see how you were making your door, since I'm in the process of making my two sets of bi-fold doors. Keep up the good work.
 

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yet another reason to invest in a tool-in 6-7 years you might volunteer to refurbish a caboose and the tool will come in handy!! Perfect plan. :)
 

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Karson, that's a specific door rail and stile set then? Really neat. My wife is itching for a new entry door. I've thought about making one, but would probably need a bigger shop, or some borrowed time on a bigger jointer. Looks great!
 

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Thanks for helping to keep part of our heritage alive Karson.
 
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