Fine Millwork. 100% American Made with Pride in Pennsylvania's Allegheny Mountains412.641.0177
Introducing our collection of premium wood French doors - where timeless elegance meets craftsmanship at its finest. These exquisite doors not only enhance the aesthetics of your living spaces but also provide functional benefits like natural light, seamless transitions, and lasting durability. Dive into the beauty and luxury of premium wood French doors in this comprehensive guide.
Unmatched Craftsmanship: Our premium wood French doors are a testament to impeccable craftsmanship. Each door is meticulously handcrafted by skilled artisans, reflecting their unwavering attention to detail and dedication to precision. Crafted from top-tier wood materials, these doors are built to stand the test of time, ensuring your investment remains a centerpiece of your home.
Customized Elegance: Experience the freedom of design with our premium wood French doors. Choose from a selection of high-quality wood species, finishes, and styles to seamlessly complement your interior or exterior. Whether your home is traditional, modern, or anything in between, our made-to-order options empower you to create doors that are uniquely yours.
Abundant Natural Light: Invite the beauty of the outdoors in with premium wood French doors. The expansive glass panes allow an abundance of natural light to flood your spaces, creating an inviting and cheerful ambiance. Whether it's a sunlit living room or a cozy breakfast nook, these doors transform your home into a bright and welcoming sanctuary.
Seamless Transitions: Create a seamless flow between indoor and outdoor spaces with wood French doors. These doors blur the line between your interior and your patio, garden, or balcony, allowing for easy transitions and effortless entertaining. Experience the beauty of bringing the outdoors closer, all while enjoying the comfort of your home.
Privacy and Sound Control: Enjoy the versatility of premium wood French doors, which can provide privacy and sound control when needed. When closed, they create an effective barrier, ensuring your personal spaces remain private. These doors also help reduce noise transmission, making them ideal for bedrooms, offices, and media rooms.
Durability and Longevity: Our premium wood French doors are engineered to withstand the rigors of time and weather. They are resistant to warping, cracking, and wear, ensuring they maintain their beauty and functionality for generations to come. Invest in doors that will endure, adding both value and sophistication to your home.
Low Maintenance, High Value: Maintaining the beauty and functionality of our wood French doors is effortless. Regular cleaning and occasional inspections are all that's required to keep them looking pristine. Unlike other home upgrades, these doors don't demand frequent replacement, making them a cost-effective and valuable investment.
Estate Millwork is one of the few french door builders left in America that uses traditional french joinery techniques for building or doors. Other French door manufactures use stave cores -- we at Estate Millwork use solid wood. Others use dowling and screws, we use traditional mortise and tenon joints, hand jointed solid stiles and a delightful array of custom sticking profiles.
We do not make our french doors cheaply, although our doors are very affordably priced for the elegant quality and craftsmanship that we offer. The trend lately has been to use faux mullions, insulated glass sheets and veneers to make a cheap doors. We still make doors in the pre-war tradition: Rich and deep sticking profiles, solid vertical grain hardwoods that have been lovingly cured in our own kilns. Each pane or "lite" is real and individual. Each mullion and muntin is carefully fitted with old world cope and stick joints. You can tell our doors from 50 feet away because they have rich texture, beautiful shadow lines and moulding, and the wonderful craftsmanship that distinguishes an heirloom quality door, from a box-store or mass producer
Our true divided light doors are ideal for both interior and exterior applications. We can offer them with tempered glass, beveled glass, or mission and georgian mosaic sticking. These doors are top-of-the-line, and we can craft them at any size, with any glass placement, and you can quickly explore are very affordable pricing using our online design tools. But if you can not create the exact custom french door that you want, please contact us via email or phone for expert personal assistance.
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.
Cypress, revered for its versatility and resilience, boasts a distinctive composition that distinguishes it within the realm of hardwoods. In its natural state, cypress exhibits a pale sapwood, which forms a minor fraction of the tree's composition. The heartwood of the Bald cypress, on the other hand, showcases a spectrum of hues ranging from a soft yellow-brown to a deep reddish-brown, occasionally presenting shades reminiscent of ebony. A general rule of thumb suggests that the darker the heartwood, the greater its resistance to decay—a testament to the wood's inherent durability.
Prized for its durability, stability, and innate resistance to water and rot, cypress wood finds its place in a plethora of construction endeavors. Whether for exterior applications such as boats, doors, shutters, or siding, or for interior uses like trim, architectural woodwork, doors, and flooring, cypress proves itself as a reliable and enduring choice.
Cypress hardwood, with its adaptable nature and distinctive aesthetics, is a sought-after species renowned for its longevity and unique character. Its warm, reddish-brown tones, complemented by intricate grain patterns, infuse spaces with rustic charm and timeless appeal. Particularly noteworthy is cypress's exceptional resistance to decay, rot, and insect damage, making it a preferred option for outdoor projects like decking, siding, and fencing, where exposure to the elements is a constant challenge.
While traditionally prominent in its native growth regions, cypress has transcended its geographical boundaries, finding favor in various applications across the United States, once dominated by cedar, redwood, and treated pine. As its versatility continues to be celebrated, cypress remains a steadfast choice for architects, builders, and artisans alike, promising enduring beauty and reliability in every project.
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
|Premium FAS Clear Grade
|Rot Resistant, Insect Resistant Premium Exterior Lumber
|3/4" X 3"
|True Mortise & Tenon,
|Strongest solid wooden joint
|1 3/8 "
|4 15/16 "
|9 15/16 "
|4 15/16 "
|1.375 " Thick
|Spline Jointed, Grain Reversed
|2 X the glue surface and strength
|Machine Sand 120, Hand Sanded 150
|Drum,Edge & Palm sanded
|Top quality hand finish
|Foam Wrapped in Custom Built Carton
|1/8" Foam, 3/16 Trim Sheet 100lb
|Protection against damage in transit.
|1 3/8" X 4 15/16" X 80"
|1 3/8" X 9 15/16" X 26 1/8"
|1 3/8" X 4 15/16" X 26 1/8"
|1 3/8" X 1 1/2" X 65 1/8"
|1 3/8" X 1 1/2" X 22 1/8"
|1/4" X 10 13/16" X 12 3/4"