Abbey Custom Door


Abbey Custom Door
Poplar Unfinished-Paint Grade
1 3/8" X 32 " X 80 " No Jamb

$893.33 Each.

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Premium High Quality Poplar Custom Doors

Discover the epitome of personalized craftsmanship with Estate Millwork's bespoke door offerings. Whether you seek to elevate the aesthetic allure or enhance the functionality of your abode, our esteemed company stands ready to fulfill your desires. Delve into a realm of boundless possibilities as we invite you to explore an extensive array of wood species, each imbued with its own distinct character and charm. From the timeless elegance of mahogany to the rustic allure of oak, our selection caters to every discerning palate.

Moreover, our dedication to excellence extends beyond mere material selection. Immerse yourself in a kaleidoscope of finishes, meticulously curated to bring out the innate beauty of each door. Whether you prefer a lustrous gloss or a subtle matte, our artisans possess the expertise to realize your vision with precision and finesse.

But the customization doesn't end there. Elevate your doors to a realm of unparalleled sophistication with our exquisite accents and embellishments. From ornate carvings to sleek hardware, every detail is crafted with meticulous attention to detail, ensuring that your doors exude an aura of refined elegance.

Embrace the opportunity to infuse your home with your unique sense of style, as our diverse range of door styles offers something to suit every taste and architectural motif. Whether you gravitate towards the timeless allure of traditional panel doors or prefer the sleek minimalism of modern designs, our collection is sure to inspire and captivate.

At Estate Millwork, we understand that your home is a reflection of your individuality, and our custom doors are designed to be nothing short of extraordinary. Embark on a journey of unparalleled craftsmanship and unparalleled beauty with Estate Millwork, where your vision becomes a reality.

Elevate Your Space: Experience Unrivaled Craftsmanship with Our Custom Wood Doors

At Estate Millwork, our commitment to quality begins with the selection of authentic, top-grade hardwoods sourced from sustainable-harvest domestic suppliers and importers. As stewards of the environment, we prioritize eco-friendly practices, recognizing the significance of giving back to the Earth that sustains our craft.

For our discerning clientele, we offer a diverse range of exquisite hardwood options, including oak, teak, maple, mahogany, and cherry wood. Each selection undergoes rigorous scrutiny to ensure it meets our stringent standards of excellence, free from any imperfections or blemishes. Our skilled artisans meticulously shape and refine the wood, crafting doors that exude unparalleled beauty and durability.

Embracing traditional craftsmanship, every Estate Millwork door is meticulously assembled using time-honored 18th-century mortise-and-tenon joinery techniques. This ensures superior structural integrity, eliminating the need for inferior glue or dowel-rod connectors. Notable features such as double-tongued and feather-tenoned base rails, precision-cut louvers, and impeccably finished solid wood frames further exemplify the exceptional durability and craftsmanship inherent in our doors.

Unlock Your Unique Style: Experience Tailored Excellence with Our Custom Door Creations

Step into the realm of unparalleled customization with Estate Millwork's revolutionary Custom Online Design Tools, empowering customers to meticulously tailor their doors to exacting specifications. Gone are the days of settling for off-the-shelf solutions; now, you have the freedom to dictate the dimensions of your doors, ensuring a seamless integration into your home's unique aesthetic.

Our intuitive design interface allows you to specify not only the height, width, and depth of your doors but also grants access to a myriad of classic door styles through a comprehensive drop-down menu. From timeless elegance to contemporary chic, each style serves as a canvas for your creative vision.

But the customization doesn't end there. Dive deeper into personalization by selecting from a rich assortment of premium wood types, finishes, and optional add-ons such as weather stripping, jambs and stops, beading, and privacy panels. Craft doors that not only complement but elevate your living space, enhancing both functionality and allure.

For those with discerning tastes and a penchant for bespoke craftsmanship, our artisans stand ready to bring your visions to life. Whether inspired by a fleeting idea or armed with detailed sketches and AutoCAD drawings, entrust us with your concepts, and watch as they materialize into tangible works of art. From precise cuts to exquisite staining, each element is meticulously tailored to harmonize with your home's decor and architectural nuances, imparting a sense of inherent value that transcends mere aesthetics.

With Estate Millwork, your doors become more than just functional elements—they become enduring investments, imbued with the essence of craftsmanship and tailored to your exact specifications. Experience the transformative power of customization and unlock the true potential of your living space.

Enhancing Energy Efficiency: Elevate Your Home with Estate Millwork's Eco-Conscious Door Solutions

At Estate Millwork, we uphold a steadfast commitment to excellence by exclusively utilizing the finest genuine wood in crafting every single set of doors. Unlike inferior alternatives like cheap particle board filler and veneer, real wood offers unparalleled insulation capabilities, ensuring optimal temperature regulation within your home. Our robust and weighty doors not only promote superior insulation but also facilitate efficient airflow, contributing to a more comfortable living environment year-round. It's not uncommon for our discerning clientele to notice a tangible reduction in their heating and cooling bills after installing Estate Millwork doors.

Furthermore, our dedication to environmental sustainability extends beyond mere rhetoric. While our competitors' doors succumb to warping, cracking, and fading, ultimately meeting their demise in landfills, our genuine wood creations stand the test of time. Solid hardwood possesses inherent resilience, capable of withstanding decades of exposure to sunlight, inclement weather, foot traffic, and everyday wear and tear. By choosing Estate Millwork, you're making an investment in longevity, ensuring that your doors endure for generations to come.

Moreover, our commitment to bespoke craftsmanship means that we can tailor custom doors precisely to your specifications, ensuring that every aspect—from dimensions to design details—reflects your unique style and preferences. With Estate Millwork, your doors aren't just functional elements; they're enduring statements of quality and craftsmanship, imbued with a timeless elegance that transcends fleeting trends.

Discover the Depths of Customization: Explore Our Custom Door Offerings

For further details regarding our exquisite wooden doors, don't hesitate to reach out to one of our dedicated Estate Millwork customer service representatives. Whether you prefer to fill out the provided form or speak directly to us, you can contact our toll-free service line at 412.641.0177 . Let us assist you in crafting the stunning, environmentally-conscious, all-wood doors that you truly deserve.

Wooden Doors Fabricated from Premium Lumber Grades

Solid Wood Doors Built with Premium Grade Lumber

Stain Grade Lumber

For our louvered door products ordered in stain grade, we use FAS clear hardwood grades for both domestic and imported lumber. For projects requiring environmentally sensitive grades, we also offer FSC certification when required. We procure all of our lumber electronically, and order only the FAS clear grades. Additionally, we pre-select and inspect each shipment of lumber, and moisture check to insure that it meets our 8% standard. And as part of our routine quality process, each board from a unit of lumber is inspected as part of our quality louvered door manufacturing process.

Paint Grade Lumber

Even our economical paint grade louvered doors are manufactured from FAS grade lumber. The FAS specification controls the type of defects that are permitted, including knots, which we exclude from our paint grade products. However, features that would be considered defects in stain grade products -- color streaks, mineral discoloration etc, are not pertinent in paint grade. Typically, we use Poplar and occasionally Oak and Soft Maple for our paint grade products.

Color and Grain Matching

For high end louvered doors, we can offer a pre-selection service whereby all of the lumber required for the entire louvered door job is picked, inspected, and designated to be assembled as a unit at one time, which often results in boards from the same tree ending up in the same door for maximum consistency. When specified we can also book match raised panels and flat panels when used in our louvered doors.

Milling and Sawing Specifications

For our highly discriminating louvered door customers, we can offer our various hardwood species to be sawn in certain way, to emphasize a desirable feature of the wood. If required, the door material can be specified as flat-sawn, quarter-sawn, rift-sawn or ribbon sawn. Talk with your Estate Millwork louvered door specialist to inquire about adding these specifications to your order.

Top Quality and Elegant Custom Wood Doors

Estate Millwork creates each custom wood door from your detailed specifications. We use premium materials, state of the art equipment, and an experienced, quality oriented staff to produce our doors. We follow each of the steps below to produce the finest wooden doors on the market.

Hand Selection and Inspection of Materials

Our lumber procurement process is computer driven so that we are sure to be getting the best possible price on the highest quality materials. Once your order is "green-lighted" for production in our plant, the lumber demand is compared to our shop inventory and automatic replenishment orders are placed if necessary. When production begins on each custom door, the material is hand selected and the best of our high quality stock is used for the solid stiles of the doors. Louvers and rails are generally selected from the same lot of material to afford the best match, within the natural variation of hardwoods.

Precision Ripping of Rails and Stiles

We minimize the costs of our high quality products by maximizing the yield on the rough lumber. Once the lumber of the appropriate thickness has been selected, it is passed through our ripping department where a specialized gang rip saw is used to get the maximum yield from each board. Our operators are trained to reject defective materials either during the selection process or during the sawing process, as some defects are latent and are not visible until the board is "opened up".

Hand Jointing of All Door Components

The next step is to hand joint each rough sawn board to get a true flat edge, and to relieve any internal stress in the solid wood. This is a step that is skipped by many modern door manufactures, but one that we believe is so important that we honor the tradition. Our most skilled craftsmen in the plant are responsible for this function which requires judgement, precision and experience. Lower quality door manufacturers skip this step, or use particle cores and veneers to fake the look of a real door. But by hand jointing each board, we insure that every other step in the process is operating on a flat, smooth board, and that the door will remain stable for its lifetime.

Precision moulding of all door components

Once the rails and stiles have been ripped to width and jointed on one face, we process them through a 5 headed moulder which reduces the wooden door components (rails, stiles, louvers) to their final cross sectional dimensions and profiles. We offer 3 stock louver sizes, but can customize them to any other size or profile. Again, at this phase, parts are inspected for defects to make sure that the final piece meets our high standards

Precision CNC Machining of Mortises, Tenons and Louver Slots

Because we do not cut corners, we also use old fashioned, but time tested joinery. Our doors are held together with true mortise and tenon joints, rather than the cheaper, less time consuming and lower quality options of dowels, screws, or biscuits. Our mortise and tenon joints are so precise and tight fitting that gluing the doors is not even necessary, they hold themselves together. Our CNC eqiupment is accurate to .001 inch, and is automatically programmed by our advanced plant management system that monitors your order as it proceeds through each department. Our CNC operators are highly skilled and go through a year of specialized on the job training where they learn the safe operation of the equipment, and advanced techniques like radius and pattern machining.

Hand Assembly by Experienced Craftsmen

Once all of the custom door parts are completely machined, they are pre-sanded and then hand assembled by a team of meticulous craftsmen. On fixed louver doors, the louvers are hand beveled and inserted into the deep seat louver mortises in the stiles, and then the entire door is clamped in a clamping system while the pegs are drilled into the tenons. Operable Louver doors are assembled in a similar fashion, where each louver is set in a nylon bushing for maximum life, and a custom louver rod is attached to the louvers to give trouble free, friction free operation for many years.

Machine Sanding to tolerance

Once the door has been completely assembled, it goes through our machine sanding department -- giant sanders big enough to sand garage doors are used for multiple passes to bring the surfaces to their final dimensions and grit. In most cases our doors are machine sanded to 150 which removes most visible roughness.

Hand Sanding.

The final step in our process is the hand sanding of the doors to break edges, and to finish sand areas that are not sanded by the machine process. Our finishers are the best in the business and during this phase, they carefully inspect the finished product and either prepare it for paint or stain, or carefully pack the door for shipment.

Poplar: The Versatile Alternative

Poplar Wood Grain

Often overshadowed by its more illustrious counterparts, poplar hardwood is an unsung hero in the world of woodworking. While lacking the bold coloration and striking grain patterns of its peers, poplar possesses its own understated charm, with a pale olive-yellow brown heartwood and lighter off-white or gray sapwood tinged with subtle greenish hues.

Widely distributed across North America and Europe, the poplar tree boasts rapid growth and abundant availability, making it a sustainable choice for various applications. Its propensity for large, clear sections makes it particularly sought after for secondary uses or applications where visibility is not a concern.

Though considered relatively soft, poplar is classified as a hardwood, ensuring durability and stability despite its softer texture. Its ease of workability is a boon for craftsmen, readily yielding to machining, sanding, and finishing processes. While often relegated to painted or secondary roles, poplar shines as a stain-grade species, gradually deepening in color over time to a richer shade of brown, earning it the affectionate moniker of "poor man's Cherry."

Versatile and affordable, poplar hardwood opens doors to a myriad of possibilities in woodworking and interior design. Its neutral color palette provides a versatile canvas for a range of finishes, from traditional to contemporary, allowing for seamless integration into diverse aesthetic schemes. Whether crafting custom cabinets, intricate moldings, or sleek furniture pieces, poplar's easy workability and consistent texture ensure a smooth and enjoyable woodworking experience.

Moreover, poplar hardwood is an environmentally conscious choice, with its sustainable growth and renewable nature aligning with eco-friendly practices. As a readily available and rapidly growing resource, poplar offers a responsible option for those mindful of environmental impact. Embrace the versatility and affordability of poplar hardwood in your next project and discover the endless possibilities it brings to the table.

Handcrafted with Sustainably Harvested Lumber

At Estate Millwork, we employ a meticulous process to ensure the quality and sustainability of our lumber. Our commitment begins with the careful air drying of much of our lumber, followed by further refinement in low wattage dehumidification kilns to achieve optimal moisture levels.

Every single piece of wood we acquire undergoes thorough utilization in our production processes. Leveraging advanced automated saws and optimization software, we achieve an exceptional yield ratio of 94 percent. This means that nearly all of the wood we purchase is transformed into usable products. The small remainder, comprising mainly sawdust and chips, is utilized efficiently: either utilized as fuel to power our operations, or repurposed by providing bedding and contributing to composting for local cattle farmers.

Our dedication to minimizing waste extends to the sourcing of our materials. A significant portion of the lumber we use hails from Amish farmers within our county. These farmers adhere to traditional practices, utilizing horses for harvesting and operating vintage 1920s sawmills. Such methods not only contribute to the preservation of heritage techniques but also entail lower environmental impact compared to modern industrial approaches.

Furthermore, our commitment to sustainability is evident in the sourcing of our imported lumber. We exclusively procure lumber from plantation-grown sources, thereby ensuring that our operations do not contribute to deforestation or the depletion of natural forests. By prioritizing responsible sourcing and efficient utilization, Estate Millwork strives to uphold environmental stewardship while delivering exceptional craftsmanship.

To learn more about our sustainability practices click here

MaterialPoplarPremium FAS Clear GradeRot Resistant, Insect Resistant Premium Exterior Lumber
Joinery3/4" X 3"True Mortise & Tenon,Strongest solid wooden joint
Frame Thickness1 3/8 "Solid WoodRigid Integrity
Stile Width5 "Hand JointedVertical Stability
Base Rail10 "BalanceArchitecturally Correct
Crown Rail5 "BalanceHistorically Accurate
JoineryDowel PlugHiddenUnobtrusive Quality
FinishMachine Sand 120, Hand Sanded 150Drum,Edge & Palm sandedTop quality hand finish
PackingFoam Wrapped in Custom Built Carton1/8" Foam, 3/16 Trim Sheet 100lbProtection against damage in transit.
2Left.Stile,Right.Stile 1 3/8" X 5 " X 80 " Poplar
1Base.Rail 1 3/8" X 10 " X 26 " Poplar
1Crown.Rail 5 " X 5 3/8" X 22 " Poplar
3BoardField.Left.VGrooveBoard,BoardField.Center.VGrooveBoard,BoardField.Right.VGrooveBoard 1 3/8" X 7 13/16" X 65 " Poplar
Custom Doors Picture