If you want custom doors for your home, look no further than Estate Millwork. Our company provides customers like you with endless choices - including wood types, finishes, accents, and styles - for doors that are tailored to suit your tastes.
All Estate Millwork doors start with genuine, top-grade, hardwoods. We partner with sustainable-harvest domestic wood suppliers and importers to deliver eco-friendly doors and other wood products. Door manufacturers require so much of the Earth, and our corporate mission embraces the goal of giving back to the planet that allows us to work at our craft.
Customers can choose from several beautiful, durable hardwoods for their doors, including oak, teak, maple, mahogany, and cherry wood. We select cuts of hardwood that are free from pockmarks, blemishes, or imperfections, and carefully cut and shape the wood to produce unquestionably gorgeous doors.
Each of our doors is assembled using 18th-century mortise-and-tenon joinery. All pieces are precision-cut, so our wood doors hold up without the aid of cheap glue or flimsy dowel-rod connectors. Other features that signify the durability of our doors include double-tongued and feather-tenoned base rails, precision-cut louvers, and expertly finished solid wood frames.
Estate Millwork is proud to introduce our Custom Online Design Tools, which enable customers to tailor their doors to their hearts' content. Use these tools to determine how high, wide, and deep your doors should be. Our expert-fitted doors provide a great return on your investment. Doors that fit your home perfectly last longer while providing better weather protection and air circulation control.
The online design tools include another drop-down menu that allows you to select from several handsome, classic door styles. Customize your doors further by selecting wood types, finishes, and other add-ons like weather stripping, jambs and stops, beading, and privacy panels.
If you've got a vivid imagination, our craftsmen can create the doors you desire. Simply submit your sketches or AutoCAD drawings to our company headquarters, and our door designers will work with you to create your perfect doors. Doors that are cut and stained to suit your home's decor and architecture look great, and can add true value when it's time for you to sell.
Unlike our competitors, we insist upon only the finest genuine wood in every set of doors we make. Real wood provides superior insulation, while cheap particle board filler and veneer simply can't compete. Our heavy, sturdy doors promote excellent insulation and air flow in your home. Often, our customers find that installing a set of Estate Millwork doors can help them lower their heating and cooling bills.
Our doors are also environmentally friendly because they last and last. While the competition's flimsy doors warp, crack, fade, and end up in landfills, our genuine wood creations withstand the test of time. Solid hardwood is exceptionally hardy and can withstand decades of sun, wind, foot traffic, or scuffing. You'll be keeping your doors for a long time.
We can build custom doors to your specifications.
To learn more about our wooden doors, get in touch with an Estate Millwork customer service representative. Fill out this form or call our toll-free service line at 1.866.322.0040. We want to help you create the gorgeous, all-wood, eco-friendly doors you deserve.
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.
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.
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.
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.
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.
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.
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".
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.
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
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.
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.
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.
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.
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||Sapele||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 3/4 "||Solid Wood||Rigid Integrity|
|Stile Width||5 "||Hand Jointed||Vertical Stability|
|Base Rail||10 "||Balance||Architecturally Correct|
|Crown Rail||5 "||Balance||Historically Accurate|
|Joinery||Dowel Plug||Hidden||Unobtrusive Quality|
|Board Size||1.75 " X 6 "||V-Grooved||Traditonal Elegance|
|Batten Size||1.75 " X 6||Cove Detail||Strengh|
|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.|