Delmar Caboose Restoration #2

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Project by Karson posted 10-06-2007 03:04 AM 2378 views 0 times favorited 13 comments Add to Favorites Watch

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
Click for details

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
Click for details

Click for details

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware soon moving to Virginia †

13 comments so far

View clieb91's profile


3520 posts in 3961 days

#1 posted 10-06-2007 03:23 AM

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

-- Chris L. "Don't Dream it, Be it."- (Purveyors of Portable Fun and Fidgets)

View bryano's profile


546 posts in 3959 days

#2 posted 10-06-2007 03:35 AM

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!

-- bryano

View Thos. Angle's profile

Thos. Angle

4444 posts in 3988 days

#3 posted 10-06-2007 03:44 AM

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.

-- Thos. Angle, Jordan Valley, Oregon

View Dan Pleska's profile

Dan Pleska

142 posts in 3987 days

#4 posted 10-06-2007 04:32 AM

Nice post on the progress of making the door.

-- Dan, West Virginia,

View Karson's profile


35125 posts in 4426 days

#5 posted 10-06-2007 04:46 AM

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.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware soon moving to Virginia †

View Dadoo's profile


1789 posts in 4016 days

#6 posted 10-06-2007 01:44 PM

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?

-- Bob Vila would be so proud of you!

View Lee A. Jesberger's profile

Lee A. Jesberger

6859 posts in 4005 days

#7 posted 10-06-2007 02:29 PM

Hi Karson;

Good job on the door and the post.

Wives sure can be pesky huh? LOL


-- by Lee A. Jesberger

View lance's profile


170 posts in 4014 days

#8 posted 10-06-2007 03:09 PM

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.

-- Bob Lance, DE

View MsDebbieP's profile


18615 posts in 4186 days

#9 posted 10-06-2007 03:50 PM

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. :)

-- ~ Debbie, Canada (

View mot's profile


4911 posts in 4062 days

#10 posted 10-06-2007 04:19 PM

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!

-- You can discover more about a person in an hour of play than in a year of conversation. (Plato)

View WayneC's profile


13754 posts in 4123 days

#11 posted 10-06-2007 04:51 PM

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

-- We must guard our enthusiasm as we would our life - James Krenov

View oscorner's profile


4563 posts in 4337 days

#12 posted 10-08-2007 08:12 PM

Very professionally done!

-- Jesus is Lord!

View Bob Babcock's profile

Bob Babcock

1809 posts in 4112 days

#13 posted 10-11-2007 01:40 AM

Amazing stuff as usual Karson!

-- Bob

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