Fine Millwork. 100% American Made with Pride in Pennsylvania's Allegheny Mountains412.641.0177
When it comes to enhancing the beauty and functionality of your home or office, nothing quite compares to the timeless elegance of premium wooden louvered doors. These exquisite doors not only add a touch of sophistication to any interior but also offer a range of practical benefits. In this article, we'll delve into the world of premium wooden louvered doors, exploring their unique features, benefits, and how they can transform your living or working space.
The Beauty of Craftsmanship: Premium wooden louvered doors are a testament to the artistry and craftsmanship that goes into creating them. Crafted from high-quality wood, such as mahogany, oak, or cherry, these doors exude natural beauty and charm. The fine detailing and precision in their construction make them a standout feature in any room, becoming a focal point that effortlessly blends with various design styles, from classic to contemporary.
Enhanced Ventilation and Privacy: One of the standout advantages of louvered doors is their ability to strike a perfect balance between ventilation and privacy. The slatted design allows for the easy flow of air, making them an excellent choice for rooms where adequate airflow is essential, such as bathrooms, closets, or utility rooms. Additionally, the adjustable louvers provide control over the level of privacy, making them ideal for spaces like bedrooms and living areas.
Durability and Longevity: Investing in premium wooden louvered doors is a wise decision for those looking for long-term value. These doors are built to last, thanks to the robustness of the chosen wood species and the meticulous construction process. With proper care and maintenance, they can stand the test of time, retaining their beauty and functionality for years to come.
Customization Options: Your design preferences are unique, and your doors should reflect that. Premium wooden louvered doors offer a range of customization options, including various wood finishes, paint colors, and hardware choices. Whether you're aiming for a rustic, vintage look or a sleek, modern feel, you can tailor these doors to perfectly match your vision.
Energy Efficiency: In addition to their aesthetic appeal, premium wooden louvered doors can also contribute to energy efficiency in your home or office. The slats on these doors allow for natural light to filter through, reducing the need for artificial lighting during the day. This can lead to lower energy bills and a more sustainable living or working environment.
Maintenance Made Easy: Maintaining the beauty of your premium wooden louvered doors is straightforward. Regular dusting and occasional polishing are usually all that's required to keep them looking their best. The durability of these doors means they are less prone to wear and tear compared to other materials, making them a low-maintenance choice.
Louvered Doors custom made by Estate Millwork are premium grade solid wood doors and are easy to order online. Our mill uses 18th century joinery methods in a 21st century manufacturing plant. Our solid wood louvered doors can be fabricated with operable or fixed louvers in a variety of configurations and species of wood including poplar, cedar, mahogany, cherry, maple, oak, and teak. A marriage of cutting edge automation and old world craft allow us to produce the highest quality wooden louver doors on the market with competitive pricing.
Our premium quality doors are specified by architects, builders and discriminating homeowners because we use clear FAS premium grade hardwoods. All are milled from rough stock by Estate Millwork craftsmen to insure complete control of quality, moisture content, fresh surfaces for glue and climate control.
Both interior and exterior louvered 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 for our louver doors.
When it comes to louvered doors, our commitment to excellence sets us apart from the competition. Here's why choosing our custom louvered doors ensures superior quality, energy efficiency, and unparalleled customization:
Unmatched Quality and Durability: Our doors are meticulously crafted from a single piece of solid wood, guaranteeing superior quality and durability. Unlike many competitors who resort to inferior milling techniques, our whole-cut solid wood construction eliminates cracks, low-quality joints, and thin filler wood. This ensures that our louvered doors maintain optimal energy efficiency by preventing warm air from seeping in during winter or cool air during summer.
Energy Efficiency: By utilizing whole-cut solid wood, our louvered doors offer exceptional energy efficiency. Say goodbye to concerns about drafts or air leakage compromising your indoor climate control. With our custom design capabilities, you can tailor your door to fit your entryway seamlessly, maximizing energy efficiency and comfort year-round.
Premium Materials for Every Environment: We exclusively use the finest quality, FAS premium grade hardwoods for both our interior and exterior louvered doors. Whether you prefer the timeless elegance of cedar, the rich warmth of mahogany, the classic charm of cherry, or the durability of oak, we offer a diverse range of wood types suited to different climates and environments. From maple to teak to poplar, our selection ensures that you find the perfect match for your specific needs.
Fully Customizable: Embrace your creativity and design the door of your dreams with our comprehensive customization options. Whether you prefer to use our intuitive online tools, consult with our knowledgeable specialists over the phone, or unleash your creativity independently, we offer a seamless customization experience. Choose your preferred wood type, louver style, size, finish, hardware, and more. Additionally, we welcome fully custom projects based on your sketches or specific requirements. Our state-of-the-art milling process, combined with traditional craftsmanship, ensures that your custom louvered door reflects the elegant look that perfectly complements your interior or exterior decor.
If you have any inquiries about our interior wooden doors, exterior wooden doors, or the custom louvered door design process, our team of experts is here to assist you. Feel free to call us at 412.641.0177 to receive personalized guidance and advice, free of charge and with no obligation. Experience the difference of our premium quality, energy-efficient, and fully customizable louvered doors today.
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 louvers 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 can 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 airflow. 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 doweling, 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 proprietary 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.
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.
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 "
|1/2 " X 2 1/4 "
|Sturdy, Air flow
|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 5" X 80"
|1 3/8" X 10" X 26"
|1 3/8" X 5" X 26"
|0 SP:2.500000 Pitch:65.000000
|1/2" X 2 1/4" X 22 7/8"