We have an SP 72-IC-1 "Sub" Commute Car (blt. 1924) and have fixed up the car for utility service on our demonstration railway. However, we cannot locate ceiling panels large enough to replace the water damaged material originally on the car when we received it. We have had success achieving nice painted finishes with Masonite, but as mentioned we cannot find it that large. Any suggestions?

I have the same issue facing me with ceiling panels in some CNJ-1000 series coaches.

Suggest checking with Steamtown; I understand they were able to source large sheet materials for the restoration of their CNJ combine. I've got an invitation to visit and learn about the project, but haven't had time to make the trip yet.

Alan Maples

From what I remember, in repairing some of the CNJ cars the shop used the smooth side of indoor paneling to replace damaged ceiling panels in at least 1 CNJ coach prior to the restoration of the CNJ combine. That was during my tenure there, not sure if that method was used for other cars, but it seemed to do the job as the boards were flexible enough to make the arch and held paint pretty nicely.

Dave Crosby

We just did the ceiling in our 1918 IC Combine, #892. It's ceilings were originally "agasote" which is no longer available. We found 3/16" thick (same as the agasote originals) masonite at the following firm:

Lurie Panels
5656-T W. Clinton Ave.
Milwaukee, WI 53223 map
Phone: 262-242-9377, 800-558-9150 (toll free)

The max. panel width available was five feet, but they told us when that was gone, it would no longer be available. Four foot wide panels are standard, with various lengths available. We had to purchase 14 footers to get the length we needed, so had a fair bit of waste.

Kent McClure
Monticello Railway Museum

Dear "cwylde":
Valley Railroad renewed all interior ceiling and hip panels on 2 former CNJ coaches using .063", 5052-0 (AMS 4015) aluminum purchased in 72" X 144" sheets (we too couldn't find masonite in the size we needed).
The ceiling panels went up with ease after trimming (with a sawzall, wear gloves and goggles) and were secured pretty much like the masonite had been.
We formed the radius on the hip panels by clamping the sheet to a smooth telephone pole as a mandrel and then bending the aluminum around. After a couple of trial bends (to see how much the aluminim sprung back) we finished the rest of the hip panels in a couple of hours.
All of the pieces were fit, then taken down, primed with a self etching primer (VariPrime) and finish coated with Centari prior to installation.
After over 15 years in service they still look perfect.
Good luck!
J.David

Did a Google search for hardboard and came up with this company:

http://www.internationalhardboard.com/

Comes in 1/10", 1/8", and 3/16" with 62" width and length to 12'.

Richard Wilkens

My brother is a general contractor and was able to get 12' Masonite panels through his supplier in San Andreas, CA. They were used by the PLA restoration crew on our suburban coach SP 2101. I suggest that you check with your local building supply company. They should be able to order it for you.

The problem isn't normally the length, but rather that BOTH dimensions need to be larger than the commonly available 48 inches.

I would suggest that you go with a veneered plywood for you ceiling panels.

Back in the late 70s and early 80s we did a lot of looking for ceiling panels. At the time most museums either spliced panels together with a noticeable seam or they used 4' x 8' panels with the grain running the wrong direction. We were on the verge of building a plywood press to make our own panels when we got a lead on a source. It was suggested that we contact Algoma Hardwoods.We called their plywood division and told the gentleman on the phone that we needed a 5' x 8' x 1/4" white maple panel. We need that size so we could run the grain the 5' direction and not the usual 8' direction. He then told us that we did not want a 5' x 8' panel. He told us we wanted 8' x 5' panel. He explained that the second number indicated the direction of the grain.

If you look in , I believe, the second issue of L&RP Magazine you will see the results of our efforts to get the right size ceiling panels.

All well and good, but I was under the impression that they were replacing original panels made of a composite material such as Agasote:

http://www.pinnacleboard.com/about.html

Unfortunately, this stuff ranks right up there with unobtainium for availability.

I agree, if one is restoring a car that had visible grain in the headlining, it needs to be the correct species and run the right direction.

Here is a response I received when emailing the Masonite Corp.

"Masonite does not manufacture any of the hardboard products anymore. You may
try contacting a company called ABTco as they are making similar hardboard
product. They can be reached at 419-535-5921."

Their website promotes hardwood siding products rather than panels. I have not tried to contact them.

That is interesting. It's like Kleenex ceasing production of facial tissues to focus on making tissue-oriented craft supplies. They should probably not have gone into the exterior hardboard siding business. I understand they are currently in deep financial trouble.

Anyway, if it helps any, the generic name is "tempered hardboard." I am sure there are a lot of shipping containers from China full of the stuff.

Check with Georgia Pacific - they make the stuff and in 5ft wide pieces. I had this problem about 10 years ago sourcing replacement panels for a heavyweight office car. Contacted the local GAPAC rep through Lowe's and kept tracking folks down till I found what I was looking for. They make the stuff for folks like Sauder Woodworking and other furniture manufacturers. I believe it was made in Wisconsin or Minnesota near Lake Superior. If you are a museum, they have been known to be amenable to donations as long as you pay the shipping and give them credit.

Good luck,
Mike