I had the task of repairing the old telephone box, as the bottom rail of the door had rotted away completely. This iconic red village telephone box has stood as a beloved fixture in Widdington for decades, but time and weather had taken their toll on its wooden door.

I carefully removed the door from the kiosk and being heavy placed it on my wheelbarrow before returning to my workshop, scratching my head and wondering how best to renew the missing bottom rail section. The rest of the door frame was surprisingly sound; only the bottom of the side stiles needed a new piece half-lapped in.

I decided to make up a new bottom rail from a couple of piece of hardwood to ensure strength and durability while matching the original as closely as possible. 

Next, I selected suitable pierces of timber for the project and began joining these up to match the original bottom rail width. My goal was to create a piece that looked origenal and had always been part of the door, preserving the historical authenticity that makes these telephone boxes so special.

I prepared the door’s side rails by carefully cutting back and removing the rotten part of the wood till only sound wood remained. I fitted the new bottom rail using traditional mortise and tenon joints to ensure a lasting repair.

After sanding everything smooth, the door looked perfect, sturdy, and true to its original form — ready to swing open once more and welcome passersby.

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 hight the bottom rail had been.

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.

The incorporation of a mortise and tenon joint in the bottom rail significantly increased the structural integrity of the lower section, ensuring it remains square and stable under load. Furthermore, the entire assembly is mechanically fastened to the steel window frame using screws, providing additional rigidity and preventing any movement over time. 

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 nice snug dry fit 

All Looking good 

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

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