Sue - wow! thanks - I did the same thing in going through all their occupations and also found Daniel in the 1841 but I had trouble finding him in the 1851 and 1861 census. And it is great that Thomas is in the 1851 and not in the 1861 census. I will look at the dates of the censuses and see if a 1839 date would work. It could.
I am leaning toward that being the one and will research it a bit more but you've given me a great start! This would also lean towards an immigration date near 1857 - he would have been 18 and probably have learned the trade from his father.
I've looked through the historical newspapers from Chicago and I did find some marriages and obits. Also from the voter registration records, I can see that Thomas' son Alfred moved out with his new wife and then in 1889 moved back to his father's house. I think Thomas died in 1889 and Louisa died before the 1900 census. I will try to find her in a 1890 census but that one is quite incomplete.
Thank you!