Telephone box repair

Widdingtons Telephone box door repair 

Widdingtons Telephone box door repair 

I had the task of repairing the Telephone box door that had rotted away some years earlier.
I carefully removed the door from the kiosk and returned to my workshop scratching my head and wondering how best to renew this bottom rail section.

Here you can see the screws and rivets.
The bottom rail was compleatly missing.

Before removing the door from the kiosk i had marked the stiles from the floor so i knew what size the bottom rail need to be.

I removed the window rivets along with the steel glazing frames.
This  gave me access to the screws that were attached to the timber door. 
I was  in luck as i didn't have to remove any of the glass panels just the beads.

I decided there was enough good meat left on the stiles to cut a decent half lap joint.
After I cut the half laps joints I started gluing up the bottom rail.

With the mortise and tenon joint on the bottom rail the lower section became very strong and  i was happy that it would keep everything square also the lower section is screwed to the steel window frame so its not going anywhere.   

I didn't feel the need for wedges what with modern waterproof glues and a tight fit joints 
I  felt its not going anywhere. ONLY TIME WILL TELL...

Cutting the half lap joint on one of the lower stiles 

A dry fit 

Looking good 

I used a router to round over the inside edge to match the existing.

Time to glue and cramp.

A little light sanding and we are there.
I noticed there was rot around the pull handle so another patch was needed.

I gave the door a coat of primer and refitted the door for others to paint.
I will take a photo when its done ...

Thanks for looking 

Our  Village telephone box is now an art gallery for local artist