Estate Millwork manufactures custom solid interior doors using 18th century joinery methods in a 21st century manufacturing plant.
Our Custom Interior Doors can be fabricated with raised panels, flat panels, true divided lights, insulated glass or mirrors in a variety of configurations and species of hardwood. Everything is made to order from fine oak, mahogany, cherry, maple, alder, ash, pine and walnut. Even though our custom interior doors are hand made to your exact designs and specifications, we are able to deliver them at a very economical price. Use our Interior Door Designer to quickly design and price your custom door, but if you need further customizations, call us or fax/email drawings.
We can make your custom interior doors in stain or paint grade, as well as handsome exterior doors that can be used as components in entry systems with site lights and transoms.
Browse through some of our standard designs of interior and exterior doors (Everything we do can be easily customized).
Our premium quality interior and exterior are specified by architects, builders and discriminating homeowners because we use clear FAS premium grade hardwoods, all milled from rough stock by Estate Millwork craftsmen to insure complete control of quality, moisture content, fresh surfaces for glue and climate control.
Our custom interior doors feature solid hardwood authentic hand-crafted construction, double tongued and feather tenoned base rails, deep pocket mortise and tenon joinery, floating panel frames, deep seated louvers, custom sizing, historic profiles and proportions, and are 100% American made. Many factory priming, painting and finishing options are available.
Louvered Doors can be ordered in a sliding or bypass configuration for closets or rooms whereby the louvered door is received by an opening in the wall, either on one or both sides of the opening. Commonly used for larger doors that partition walk in closets, rooms, or living spaces, pocket doors are a very convenient way to quickly separate or unify spaces. When open, the doors are not visible. Probably the most complicated method for installation, it often requires pre-planning, for the removal of studs and the addition of headers, and it is most economically done in new construction. However, it is a very common application in well-built older homes as well, and Estate Millwork can exactly match your existing pocket doors if they need to be replaced, or to be used in a remodeling.
Each louver in our louvered doors 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 door 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 door is seated in a 7/16" deep mortise in the door 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 doors 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 door. Unlike many custom door 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 door manufacturers as too expensive. Because we have invested heavily in automation, our cost to produce highly custom louvered doors 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 door frame, and when combined with our hardwood dowling, the door frame will stay together and be extremely stable, even without glue. But of course we use glue for added strength. For larger louvered doors, 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.
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.
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.
|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 3/8 "||Solid Wood||Rigid Integrity|
|Stile Width||5 "||Hand Jointed||Vertical Stability|
|Base Rail||10 "||Balance||Architecturally Correct|
|Crown Rail||5 "||Balance||Historically Accurate|
|Louvers||1/2 " X 2 1/4 "||Solid, Bullnose||Traditional Detail|
|Louver Pitch||-67.5 Degrees||Fixed Louvers||Sturdy, Air flow|
|Louver Spacing||1.875 "||Variable Options||Customizable|
|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.|