Constructed using hand-selected, whole-cut solid woods, interior louvered doors from Estate Millwork can be custom designed to accentuate any size of entryway. Solid wood-constructed louvered doors offer an elegance that is timeless and unsurpassed in quality. Doors can be constructed with operable or inoperable louvers and additionally fitted with numerous styles of hardware fixtures. Simply put, when you combine top-quality, hand-selected woods such as teak, mahogany or cedar with age-old techniques and modern automation implemented by Estate Millwork, your interior louvered doors will make a lasting statement like no other.
The techniques and materials that are used by Estate Millwork create a finished product in your interior doors that goes beyond aesthetics. Interior louvered doors from Estate Millwork are a lasting investment due to their quality and craftsmanship. They not only help to regulate hot and cold temperatures thus saving you on your energy costs, but our doors make use of no thin wood fillers or low-quality joins that could make them more easily susceptible of cracks or warping over time. Certain woods that we exclusively use, such as Spanish cedar for example, even have a natural resistance to fungus and termites. And Estate Millwork uses only FAS (first and seconds) top-quality woods that produce interior louvered doors that will retain their beauty while continuing to function in the most durable manner for your home.
Because of their versatility and timeless aesthetic, interior louvered doors offer an adornment that is unmatched in elegance and durability. Top-Quality woods such as cherry, maple, teak, poplar and cedar that Estate Millwork use extensively offer striking exuberance to any entryway. The countless variety of styles, patterns and materials available to you results in interior louvered doors that can make an impact in a classically designed room just as easily as they can lend their beauty to a modern space.
With experts that can work diligently with you every step of the way, there is virtually no limit to the style or design that Estate Millwork can fabricate for your own set of interior doors. While we do offer preselected designs, you can choose to personalize every aspect of your interior doors. Choices include style, dimensions, custom carvings and even hardware. Estate Millwork can even take an original sketch of an interior louvered door design and work closely with a customer to bring an imaginative idea to life. There are also multiple factory finishing, priming and painting options for you to choose from to finalize your own interior louvered doors that will match your home and personality. You can get started with our louvered door designer to mix and match some patterns and designs in order to help you to have an idea of the endless options available to you in creating your own custom louvered doors. When you are ready to bring your ideas to life, you can contact a custom interior louvered door specialist at Estate Millwork at 1.866.322.0400 and have all of your questions answered or just be guided through the process itself.
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 lovered 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 "||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.|