Estate Millwork's Colonial Collection styles of exterior window shutters are all whole cut and hand crafted for superior quality. Each window shutter can be custom designed to the exact size and proportion that is required. This ensures that your shutters will fit perfectly in your window and improve the efficiency in which your home or business can be heated and cooled. All of our window shutters are historically accurate both in terms of their construction and design. Prominent in Early America, these shutters were used for both decoration and defense (from the weather of course, but also from robbers, British and the Indians). Classically styled and highly durable, this type of exterior window shutter is appropriate on Colonial, Georgian and Federal styles of architecture.
Each exterior window shutter comes standard with flat panels, 1/2" thick, but can be customized with thicker shutter panels up to a musket ball stopping 1 3/8" inch. The shutter frame thickness for the exterior window shutters is 1 5/16. However, these can also be ordered multiple configurations in a variety of flat panel and frame thickness. All of our flat panels are joined, not with a typical butt glue joint, but with a 3 tongued interlocking spline joint which doubles the strength of the panels at the joints. Our Colonial shutters are fully operational, but can also be used as decorative exterior window shutters -- view our line of shutter hardware to find the perfect compliments and accents for your shutters.
Beginning with sustainable forestry and ending with an energy efficient climate control solution, our exterior window shutters are the perfect solution for the environmentally conscious consumer. The woods for our shutters are grown in the Allegheny Mountains of Western Pennsylvania using sustainable forestry. The lumber is then processed in our energy efficient low consumption mill. Saw dust is gathered and donated to local farmers for cattle bedding and composting, and much of our power is harvested from local windmills. Our exterior window shutters continue to save energy when they are installed in your home. The ability to customize the size and design of your window shutters allows for a perfect fit that will reduce air seeps. Additionally, the solid wood construction of our exterior window shutters further seals your home to keep you cooler in the summer and warmer in the winter while expending less energy.
Estate Millwork's exterior window shutters provide an industry leading example of quality old-world craftsmanship and high durability. It is important to note that most of our competitors mill their window shutters from a combination of multiple pieces of low grade wood wrapped with high grade wood, causing them to be less energy efficient and less durable. This gives their wooden shutters the appearance of being high quality full cut shutters without having to use high quality construction techniques. In addition to the superior materials that you have to choose from, our complete customization options ensure a superior window shutter that matches your needs and fits your commercial space or home perfectly.
Energy Efficient Exterior Window Shutters - As we have mentioned, our window shutters are all constructed from whole cut solid wood. This is the best most durable and energy efficient option for your home because it will ensure that the window shutters do not have cracks, weak joins, thin internal insulating woods, or other inferior quality milling processes and materials that can cause exterior window shutters be less energy efficient. Our custom window shutters design process ensures that our shutters match the size of your windows seamlessly and will protect your home or office cooling and heating expenses with the most energy efficient wooden shutters on the market today.
Superior Durability - The highest premium grade, FAS hard woods are hand selected and hand cut in the fabrication of both our interior window shutters and exterior window shutters. Choose from mahogany wood, poplar wood, cherry wood, teak wood, cedar wood, maple wood, and oak wood. Different wood stocks have varying tolerances to regional climates. , Please feel free to call our window shutter customization experts at 412.641.0177 for assistance if you are unsure about which materials are best suited for your climate.
Completely Customizable Shutters- Receive the shutters that provide the perfect compliment to your commercial space or home with:
You have full customization options for your window shutter type, style, size, finish, hardware and more! We also have the ability to mill fully custom interior and exterior window shutters from your hand drawn or rendered sketches! Our highly effective synergy of automation and old world craft ensure that you receive the elegant look that matches your interior or exterior decor perfectly.
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.
Each louver in our louvered shutters is precision machined in a 5 head moulder that can be configured to mould any of our 3 standard production profiles, or custom profiles as specified by the customer. We offer 1/2" X 2 1/4", 3/8" X 1 3/4", and 1/4" X 1 1/4" bullnose profiles, but also have tooling for chevron, beveled, and other louver profiles. Whether the louvered shutter is to use fixed louver or operable louvers, we can even create custom tooling to match existing millwork, or to provide the ultimate in personalization and detailing.
Each louver in a fixed louvered shutter is seated in a 7/16" deep mortise in the shutter stile. Our CNC machining equipment be instantly programmed to program any variation of louver size, profile, pitch, and spacing, that gives us unlimited flexibility to match historic millwork, or to create custom louvered shutters to a precise specification in terms of louver count, rail placement, and air flow. In the same pass as the louver mortises are being created, our equipment also creates the larger mortises for each rail in the shutter. Unlike many custom shutter manufacturers today, Estate Millwork does not use cheap dowels, veneers, screws, or biscuits. Instead we use old fashioned mortise and tenon joints, even though they are considered by other custom shutter manufacturers as too expensive. Because we have invested heavily in automation, our cost to produce highly custom louvered shutters using solid materials and premium joinery is much lower than other manufacturers, hence: higher quality, lower price.
The tenons on both ends of each rail are engineered to give maximum stability to the louvered shutter frame, and when combined with our hardwood dowling, the shutter frame will stay together and be extremely stable, even without glue. But of course we use glue for added strength. For larger louvered shutters, we use a 10 inch baserail that has two tenons and a third feather tenon for additional strength that connects the two main tenons. These tenons are precision machined on a propriety tenon machine that Estate Millwork designed and custom built. Our sophisticated mortise and tenon joinery preserves 100% of the quality of traditional mortise and tenon joinery at a fraction of the cost.
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.
Poplar hardwood lacking bold coloration or an exciting grain pattern has a pale olive-yellow brown heartwood and sapwood is lighter off-white or gray with greenish hues and doesn't often get the respect we feel it deserves. The Poplar tree is widespread across all of North America and Europe, and it grows very rapidly and to large sizes, making it very easy to sustain.
Because the wood is often painted or used in secondary applications where it isn’t visible, it is very easy to find wide, clear sections of Poplar for a variety of uses.Poplar lumber is pretty soft and very easy to work. But botanically speaking it is a hardwood meaning it is a deciduous tree. But it is highly stable, easily available in width and length, and takes paint and stain famously well. However using Poplar as a stain grade species is often overlooked. Some will call Poplar wood "poor man's Cherry" as it oxidizes over time to a much darker shade of brown.
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||Poplar||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||3/8 " X 1 3/4 "||Solid, Bullnose||Traditional Detail|
|Louver Pitch||-67.5 Degrees||Fixed Louvers||Sturdy, Air flow|
|Louver Spacing||1.375 "||Variable Options||Customizable|
|Applications||Built to your requirements|
|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.|