Adams Flat Panel Door

1

Adams Flat Panel Door
KnottyAlder Unfinished-Paint Grade
1 3/8" X 32 " X 80 " No Jamb

$665.32 Each.

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Premium High Quality Knotty Alder Flat Panel Doors


When it comes to transforming the ambiance of your living spaces, nothing exudes elegance and warmth quite like premium wooden flat panel doors. These doors are not just functional barriers; they are a statement of timeless beauty and craftsmanship. In this article, we'll explore the myriad benefits of choosing premium wooden flat panel doors for your home, how they can enhance your interior design, and why they are an excellent investment for both aesthetics and functionality.

Superior Craftsmanship: Premium wooden flat panel doors are a testament to the artistry and skill of master craftsmen. Each door is meticulously handcrafted to ensure a flawless finish and exceptional durability. The intricate details and attention to grain patterns and textures make these doors a true work of art that can instantly elevate the look of any room.

Timeless Elegance: Wood has an enduring appeal that never goes out of style. Whether your home features a classic, modern, or rustic interior design, premium wooden flat panel doors seamlessly blend in, adding a touch of timeless elegance. The warmth of wood creates a welcoming atmosphere that is both comforting and aesthetically pleasing.

Durability and Longevity: Investing in premium wooden flat panel doors means investing in doors that are built to last. High-quality wood, along with expert craftsmanship and finishes, ensures that these doors will endure for generations. Unlike some other materials, wood ages gracefully, developing a beautiful patina over time.

Customization Options: One of the significant advantages of premium wooden flat panel doors is the ability to customize them to suit your unique style and preferences. From choosing the type of wood and stain to selecting hardware and panel designs, you have the freedom to create doors that perfectly complement your home's interior.

Energy Efficiency: Wooden doors provide excellent insulation, helping to maintain a comfortable indoor temperature and reduce energy bills. Their natural insulating properties make them a practical choice for all seasons, keeping your home warm in winter and cool in summer.

Increased Property Value: Installing premium wooden flat panel doors can significantly enhance the resale value of your home. Potential buyers often appreciate the aesthetic appeal and durability of wooden doors, making your property more attractive in the real estate market.

Easy Maintenance: Contrary to common belief, wooden doors are relatively easy to maintain. With regular cleaning and periodic refinishing, these doors can retain their beauty for many years. Plus, any minor scratches or blemishes can be easily repaired, extending their lifespan.

Tailored Flat Panel Door Solutions for Bathrooms and Toilet Rooms

Estate Millwork offers a comprehensive selection of wooden flat panel doors that are meticulously crafted to serve a variety of purposes, particularly well-suited for bathroom and toilet room partitions, privacy panels, or water closet doors. Each door is individually handcrafted, imbuing it with a sense of unparalleled craftsmanship, distinction, and tradition. This attention to detail ensures that every door exudes a timeless charm, making them equally suitable for both commercial and residential settings.

Our range of bathroom doors boasts versatile configurations, allowing for customization to meet specific needs. Whether you prefer louvers, panels, or a combination of both, we can accommodate your preferences with precision. Furthermore, we offer an extensive array of hardwood species options, ensuring that your door not only meets your functional requirements but also complements your aesthetic preferences seamlessly.

In essence, Estate Millwork's wooden flat panel doors not only provide practical solutions for privacy and partitioning but also elevate the ambiance of any space with their exquisite craftsmanship and customizable options.

Crafting Custom Solutions: Flexible Thicknesses and Partition Hinging for Flat Panel Doors

Experience unmatched versatility with our wooden flat panel doors, meticulously crafted to meet your exact specifications. Choose from a full interior thickness of 1 3/8 inches or opt for a range spanning from 3/4" to 2 1/4", ensuring your door perfectly fits your design requirements.

For those seeking a timeless aesthetic reminiscent of classical locker rooms or club spaces, we recommend our stained mahogany or cherry options, exuding sophistication and warmth. Alternatively, if a paint-grade solution is preferred, our Poplar toilet room doors offer both ideal functionality and cost-effectiveness.

Beyond their flat panel design, our partition doors serve as a canvas for customization. Elevate your space with louvered doors or explore bespoke detailing options such as quirking, appliques, or patterned cut-outs, adding a personalized touch that enhances both form and function.

Crafted for Endurance: The Longevity of Estate Millworks' Flat Panel Doors

Indulge in the meticulous craftsmanship that defines Estate Millworks' flat panel doors, meticulously constructed using authentic mortise and tenon joinery techniques and precision CNC machining on premium hardwoods. Explore our website to peruse an extensive collection of door designs, effortlessly customizing and pricing the ideal toilet room door to suit your specific application needs.



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.


Exploring the Beauty of Knotty Alder

Knotty Alder Wood Grain

Knotty alder lumber originates from the knotty alder tree (Alnus rubra), a species indigenous to the Pacific Northwest, spanning regions of both the United States and Canada. Recognizable for its distinctive features, knotty alder wood captivates with its pronounced knots, intricate grain patterns, and inviting reddish-brown hue.

Celebrated for its rustic allure and remarkable adaptability, knotty alder hardwood stands out as a unique and versatile wood species. Its captivating blend of reddish-brown and pale yellow tones, accentuated by prominent knots and natural imperfections, lends a charmingly weathered aesthetic. This rustic character makes knotty alder a favored choice for instilling warmth and character into residential and commercial spaces alike. Whether fashioning rustic cabinets, artisanal doors, or striking furniture pieces, knotty alder infuses each creation with timeless natural beauty.

The distinctive grain patterns and warm color variations of knotty alder hardwood make it a preferred selection among designers and craftsmen seeking to craft eye-catching and distinctive works. Beyond its aesthetic appeal, knotty alder is renowned for its workability and finishing ease. Whether seeking a clear finish to accentuate its natural allure or a deeper stain to amplify its rustic charm, knotty alder adapts effortlessly to your creative vision.

With our extensive assortment of knotty alder hardwood options encompassing various grades, sizes, and cuts, you possess the flexibility to manifest your creative aspirations. Whether an experienced artisan or a homeowner embarking on a renovation journey, our knotty alder hardwood ensures unparalleled quality and performance. Embrace the unique beauty and versatility of knotty alder hardwood. Explore our diverse collection today and unlock the potential to transform your living spaces into inviting havens resonating with the timeless charm of knotty alder. Choose knotty alder hardwood and yield enduring, enchanting results for your next project.

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


MaterialKnottyAlderPremium 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
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.
QuantityDescriptionDimensionsMaterial
2Left.Stile,Right.Stile 1 3/8" X 5 " X 80 " Poplar
1Base.Rail 1 3/8" X 10 " X 26 " Poplar
2Base.StileMortise 2 " X 4 1/2" X 9 5/8" Poplar
5Dowel.Dowel 3/8" X 3/8" X 1 " Poplar
2Crown.Rail,Dividing.Rail 1 3/8" X 5 " X 26 " Poplar
4Crown.StileMortise,Dividing.StileMortise 2 " X 4 1/2" X 4 5/8" Poplar
2FlatPanel.Flat 3/4" X 22 1/2" X 30 1/2" Poplar
Flat Panel Doors Picture