Fine Millwork. 100% American Made with Pride in Pennsylvania's Allegheny Mountains412.641.0177
Beautifully hand crafted, Estate Millwork's Bahama Shutter collection will add elegance and functionality with loads of style to your home. Distinguished from other shutters by the fact that they are hinged at the top, rather than the sides, and usually have but one shutter per window, rather than two. Ideal for warm climates, Mediterranean and Caribbean style homes, Bahama shutters add shade to windows, porches and cabanas, as well as allowing for the shifting tropical breezes to pass to the interior of the house.
Our Bahama Shutters are made from the top grades of lumber, and are designed with extra structural details that allow them to be used in even the largest scale. We have made Bahama Shutters that are in excess of 14 feet wide, with as many as 7 sub-stiles. Our standard thickness is a stout 1 5/16, and because these shutters are constructed with top grade hardwoods and true deep pocket mortise and tenon joinery, they are much stronger than most other brands. They can be fitted with louver blades of any size and shape, and for some applications, our customers equip them with operating louvers that allow the louvers to be fully open or fully closed, or anything in between.
In order to maximize the durability of our exterior Bahama shutters, they are hand assembled by master craftsman using parts that are made in our state of the art plant. Our workers are skilled at the old world art of mortise and tenon joinery, and have a knack for assembling these elegant masterpieces in wood that sometimes can have more than 500 parts. Each shutter is joined with precision joinery, doweled and machine sanded. Then, depending upon the application, it will be hand sanded, primed, painted or stained.
All of our Bahama Shutters are built to order, and we can work from sketches, photographs, CAD files, or existing shutters. Our goal is to make the perfect shutter for each application, and perfection is a combination of proportion, dimension, style and craftsmanship. We can work with you to meet your exacting requirements, and because of the high degree of automation in our plant, we are able to produce completely custom, furniture grade millwork at very competitive prices, often at prices lower than manufacturers using inferior materials and joinery. Our website is a good starting point for your project, you can browse the styles of Bahama shutters that we offer, and get quick pricing and detailed drawings on line. You can order directly on line, or feel free to contact us with special needs or project requirements.
Our premium quality shutters are carefully constructed using a time consuming and precise operation. Whereas other lower quality shutters are made using screws, nails, dowels or biscuit joints, each of our exterior wooden shutters has a minimum of 4 hardwood tenons. The end of each rail is painstakingly machined to have a 1/2" X 1 7/8" tenon by a custom built tenoning machine that Estate Millwork developed so that we could continue to provide the best quality joinery in the industry, at an attractive price. We gave up the cost, but not the quality.
Each stile is precision machined with a minimum of two deep pocket mortises, and these mortises perfectly fit the associated tenon. Again, Estate Millwork has used precision automation to preserve the quality of our products, while reducing the cost. We have software that connects our website directly to the machines in the plant, and when a customer places an order with us, all of the precision programs for machining the mortises into the stiles are sent to the plant for automatic execution. The mortise tenon joint, is the strongest joint in millwork, and adds tremendous strength, even without the use of glue.
Once the tenon and mortise have been machined, the parts are put together and a hole is drilled through the mortise and the tenon. A slightly oversized hardwood dowel is driven into the hole, locking the tenon into the mortise for the life of the shutter. Even though glue is not required, Estate Millwork takes the added step of gluing the tenon into the mortise, and gluing the hardwood dowel into the stile.
In our commitment to preserving the best of quality millwork traditions in each wood shutter, we have automated much of the drudgery of some of the operations, but assembling a shutter is still something very much in the realm of craftsmanship. After all the parts of each wooden shutter are manufactured, one of our skilled craftsmen fits them together in a specialized jig for dry fitting and final assembly. We do not use pneumatic or hydraulic clamps as they can damage or over-stress the wood. The craftsman uses his innate feel for the materials to set the appropriate clamping pressure prior to drilling and doweling. Each wooden shutter receives the individual attention of craftsmen all along the way, but the final assembly is where the shutter comes together the first time, ready for years of service on your home.
The "slab dimensions" are the size of the actual exterior shutter from top to bottom, left to right, and the thickness. Our default standard thickness is 1 5/16", but that can be varied from 7/8" to 2 1/4" to match existing exterior shutters. The length and height can be specified to the nearest 1/16" inch. Depending upon the style of the shutter, we have made widths up to 20 feet wide, and heights up 30 feet.
Because all of our exterior wooden shutters are custom built from true rail and stile construction, we have the ability to replicate any component dimension on existing shutters, including rail height, placement, width, thickness, and stile width and thickness. Typically, the bottom rail of our custom shutters is 4. high, and all other rails are 2 1/2" inches. Stile widths are usually 2 1/2" but we have the ability to make them of virtually any width, including different widths for left and right stiles -- sometimes used for pairs of shutters.
Out standard products are S4S, or square shoulder sticking, but we have the capability to mould any feasible profile to the inner or outer frame fields. Common choices are ogee, cove and bead, bevel, cove etc. In addition to our stock sticking profiles, we can also custom grind tooling to achieve any desired profile to either match historical wood shutters, or to meet an architects or home owner.s specifications and preferences.
For operable shutters, or for decoration, our wood shutters can be machined with a bead on one face of the inside edge of the shutter, and with a ship lap on the other, allowing the shutters to overlap by 3/8" when they are in the closed position - permitting a tighter fit. The left and right shutters are machined as pairs so that in the closed position, each face of the pair has a decorative bead visible.
Our raised panel shutters can be raised with our standard scoop profile, but we offer bevels, coves, ogeees and other profiles as well. Additionally, for the extremely discriminating home owner or architect we can create new tooling to match existing historical panel profiles, or to meet with a unique custom requirement.
Our louvered shutters can be fitted with either our standard bullnose louvers in 3 sizes, or with a chevron or bevel profile as options. And because we are a custom shutter maker, we can also accommodate any special profiles that are specified by the customer.
Raised Panel and Flat Panel Shutters can have a limitless variety of decorative cut outs machined into the center of the panels. Common shapes are moons, anchors, trees, hearts and we have a large number of stock cut outs which we offer, as well as the ability to match custom patterns that are provided by the customer
Estate Millwork can ship our custom wooden shutters in natural, primed, painted or stained finishes. We can match national brand color numbers, pre-tint primers for light or dark finishes, and apply hand rubbed stain finished, even to the time consuming louvered shutters.
Walnut Hardwood Lumber is a premium domestic hardwood valued for its rich color and excellent finishing qualities. Walnut has a slightly open grain varying from wavy to irregular with an even and uniform medium to coarse texture. Walnut is a unique domestic species, because there are no other North American species of wood with the same distinct chocolate brown colored heartwood. The wood's rich tones make for excellent doors and paneling, and as a furniture wood, it is hard to beat.
Walnut gained popularity back when colonists started importing the lumber to Europe for furniture and interior woorwork, because it was so plentiful then it was easier and cheaper to obtain than Mahogany.
Today, Walnut is still highly prized for furniture and interior woodwork, but it is growing in popularity is starting to match that of Cherry. A significant development in the Walnut lumber use is in the marine industry, boat builders are now using the dark color on yacht interiors as a contrast to the lighter tones of Teak. At heart Walnut wood is a statement of luxury and is used in many applications to that effect.
Freshly milled Walnut can exhibit many different color hues, from deep browns and purples to light creams. Steaming Walnut will even out some of those color variations and creates a much more uniform and mellow chocolate color, over time and with oxidation and exposure to the sun Walnut will lighten in color and blends well with most other species.
At Estate Millwork we air dry much of our lumber, and after air drying we finish drying in low wattage dehumidification kilns.
Every piece of wood we purchase is used to the fullest on products, at Estate Millwork we have a very high yield ratio of 94 percent due to the use of automated saws and optimizing software. The remainimg 6 percent which is mostly sawdust and chips are either burned to heat our plant or send to local cattle farmers for bedding and composting.
Nothing is wasted. Some of Appalachian lumber we use comes from Amish farmers in our county who harvest with horses instead of mechanized equipment, and do our rough sawing on 1920s sawmills that are also extremely low input compared to larger commercial sawmills of today. All of our imported lumber is plantation grown, and not harvested from natural forests.
To learn more about our sustainability practices click here
|Material||Walnut||Premium FAS Clear Grade||Rot Resistant, Insect Resistant Premium Exterior Lumber|
|Joinery||3/4" X 3"||True Mortise & Tenon,||Strongest solid wooden joint|
|Frame Thickness||1 5/16 "||Solid Wood||Rigid Integrity|
|Stile Width||2 1/2 "||Hand Jointed||Vertical Stability|
|Base Rail||4 "||Balance||Architecturally Correct|
|Crown Rail||2 1/2 "||Balance||Historically Accurate|
|Louvers||.375 " X 1.75 "||Solid, Bullnose||Traditional Detail|
|Louver Pitch||-67.5 Degrees||Fixed Louvers||Sturdy, Air flow|
|Louver Spacing||1.375 "||Variable Options||Customizable|
|Finish||Machine Sand 120, Hand Sanded 150||Drum,Edge & Palm sanded||Top quality hand finish|
|Packing||Foam Wrapped in Custom Built Carton||1/8" Foam, 3/16 Trim Sheet 100lb||Protection against damage in transit.|