If folks had to pick the most famous Summer vacation spot in the United States, odds are they would say Martha's Vineyard, Massachusetts. With a long history stretching back before there even was a United States, Martha's Vineyard is blessed with good weather and fine beaches. You can not drive there. You need to take a ferry, or fly over to it. That makes it just remote enough to feel like you are getting away from it all, but just close enough so you can get back without too much trouble. Presidents and Movie Stars have liked it there for Summer vacations for a long time. If you have a home there, or want to, you'll like it there as well. And with classic Victorian and Colonial homes all around you, you will see the famous Louvered Exterior Wood Shutter gracing many of those homes.
Being a proper New England destination, proximity to the Atlantic Ocean made Martha's Vineyard what it is. And you can see that reflected in the architecture there. The Old Whaling Church in Edgartown, is a perfect example of that. Built in 1843 by local shipwrites in the Greek Revival style, it was funded by the local mariners and fishermen. It remains one of the finest examples of such classic architecture in New England. With the economic boom of the 19th Century, quite a bit of New England architecture took on a decidedly Victorian style. The town of Oaks Bluff is blessed with a style of such architecture that is almost unique to Martha's Vineyard. Known as the Gingerbread Cottage, these were small homes built in a charmingly elaborate Victorian style, often called Carpenter's Gothic. They are, and remain, treasured possessions for the lucky families that have them.
And on many of those classic homes, you will see one of the original ways for controlling the light and temperature in your home. That was the Louvered shutter. In the days before central air conditioning, you had wooden louvered exterior shutters mounted on your windows. To allow in more light and a cooling breeze in the summer, you adjusted your louvers open with the built-in Lift rods. When the rain came, and in New England it will come, or if you wanted a bit of privacy, you closed the lovers. It was simple and effective. And while doing all that, your Louvered Shutters would grace your windows, making your windows, and your home, look a lot better in the process. Louvered exterior shutters remain a classic on homes all over the world for that reason. They did their job, and looked good doing it.
And they still do look good. Quality wooden exterior shutters can make a beautiful impact on your home in Martha's Vineyard. And we at Estate Millwork are ready to make custom exterior shutters for you. It is what we do.
Give us the measurements, and we can make the perfect shutters for your home. We have worked hard to combine precision machining technology with old fashioned woodworking skills. We only work in wood. No vinyl or pressed sawdust here. You can choose from a variety of woods for your exterior wood shutters. We work in Oak, Maple, Cherry, and Cypress all the time. And we are comfortable working in exotic woods like Mahogany and Teak as well.
And did I mention the Custom part of the custom wood shutters we make? Every wood product we sell is made to order. If you need your Louvered shutters to have functional Louvers, then we can do that for you. If you just need decorative Louvers, we can do that too. In fact, all kinds of shutters are available for you. We also make Flat Paneled shutters, Raised Panel shutters, Bermuda shutters, Board and Batten shutters, and Combination shutters that give you the best of both worlds, Louvers and Panels. If you need further customization, we can do that too. Tailor made extra thin or thick Louvers, special length rails and stiles, Arched shutters, Shutter horns, decorative faux-lift rods, mouse holes, and custom mouldings are all available for you if you need them. This can be quite handy if you are restoring a classic home in Martha's Vineyard, where something out of the ordinary may be needed.
And when the storms and rain come to Martha's Vineyard, and this being New England they will come, you will be happy you have quality wooden exterior shutters protecting your windows.
Starting with top grades of rough hardwood stock, we hand-select each board. That is the only way you get durable and distinctive exterior shutters for your home. You work with the best! We keep waste to a bare minimum, improve quality, and provide our customers with durable, solid exterior shutters that outlast cheap vinyl or low-grade veneer exterior shutters. We also work with cypress, mahogany, and teak, distinguishing us from the competition.
We are always proud to make the best possible custom wood shutters for your home. Estate Millwork uses a combination of modern ingenuity and timeless craftsmanship. Our shutters feature:
Whether it's a new house, renovation, home improvement, or historic reconstruction, our exterior shutters are the right choice for your home project.
Any questions? Call 412.641.0177 – our expert customer service representatives are glad to help.
To order shutters for your home, call or e-mail our customer service team today.
Although our Louvered shutters can be ordered in a variety of materials, for use we recommend Spanish Cedar, the only Cedar that is an actual hardwood. Known for its durability, strength, and resistance to rot, fungus and insects, this premium material is used both in the rail and stile frames of the louvered shutters, as well as the actual Poplar louvers. Estate Millwork uses domestic and imported hardwoods from sustainable forests, and has invested heavily in technology and software to maximize the yield and quality of our rough Poplar lumber. Our Spanish Cedar is kiln dried to an exacting 6% moisture content, and the process of converting the rough lumber into finished dimensional stock is executed by Estate Millwork craftsmen, giving us the maximum control over the quality of our shutters.
Once our rough Poplar lumber has been processed to the correct dimensions for the final shutter, our craftsmen begin the machining or milling processes that are involved in the high quality construction technique that we use, moritse and tenon joinery. The ends of each rail are machined with a beefy 2" tenon, and the stiles are machined with mortises to receive the tenons, as well as the deep set hardwood louvers. After the computer controlled machining is completed, each louvered shutter is assembled, by hand. The tenons are fit into the mortises with 1/64" accuracy, the louvers are set in the deep louver mortises on the stiles, and everything is held fast with premium wood glues and our special, house made hardwood pegs. The hardwood cedar pegs hold the frame together, and are the strongest, oldest, longest lasting wood joint known to the art of joinery.
Our website is a starting point to quickly design and price Poplar louvered shutters. In addition to specifying the dimensions, style and material, customers can request radius tops, operable louvers, custom rail placements and frame designs. We are able to achieve a premium quality product at a very affordable price, usually less than any of our competitors, by our investment in technology, craftsmanship, and scale of operations. You can browse the online Shutters designs in the catalog, or interact with our shutter designer to get instant pricing, including discounts, on line. There are many other applications for louvered shutters, including room partitions, toilet room doors, closets, awnings and others, so please contact Estate Millwork with any questions or design ideas that you have.
Our premium quality shutters are carefully constructed using a time consuming and precise operation. Whereas other lower quality shutters are made using screws, nails, dowels or biscuit joints, each of our exterior wooden shutters has a minimum of 4 hardwood tenons. The end of each rail is painstakingly machined to have a 1/2" X 1 7/8" tenon by a custom built tenoning machine that Estate Millwork developed so that we could continue to provide the best quality joinery in the industry, at an attractive price. We gave up the cost, but not the quality.
Each stile is precision machined with a minimum of two deep pocket mortises, and these mortises perfectly fit the associated tenon. Again, Estate Millwork has used precision automation to preserve the quality of our products, while reducing the cost. We have software that connects our website directly to the machines in the plant, and when a customer places an order with us, all of the precision programs for machining the mortises into the stiles are sent to the plant for automatic execution. The mortise tenon joint, is the strongest joint in millwork, and adds tremendous strength, even without the use of glue.
Once the tenon and mortise have been machined, the parts are put together and a hole is drilled through the mortise and the tenon. A slightly oversized hardwood dowel is driven into the hole, locking the tenon into the mortise for the life of the shutter. Even though glue is not required, Estate Millwork takes the added step of gluing the tenon into the mortise, and gluing the hardwood dowel into the stile.
In our commitment to preserving the best of quality millwork traditions in each wood shutter, we have automated much of the drudgery of some of the operations, but assembling a shutter is still something very much in the realm of craftsmanship. After all the parts of each wooden shutter are manufactured, one of our skilled craftsmen fits them together in a specialized jig for dry fitting and final assembly. We do not use pneumatic or hydraulic clamps as they can damage or over-stress the wood. The craftsman uses his innate feel for the materials to set the appropriate clamping pressure prior to drilling and doweling. Each wooden shutter receives the individual attention of craftsmen all along the way, but the final assembly is where the shutter comes together the first time, ready for years of service on your home.
Each louver in our louvered shutters 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 shutter 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 shutter is seated in a 7/16" deep mortise in the shutter 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 shutters 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 shutter. Unlike many custom shutter 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 shutter manufacturers as too expensive. Because we have invested heavily in automation, our cost to produce highly custom louvered shutters 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 shutter frame, and when combined with our hardwood dowling, the shutter frame will stay together and be extremely stable, even without glue. But of course we use glue for added strength. For larger louvered shutters, 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.
The "slab dimensions" are the size of the actual exterior shutter from top to bottom, left to right, and the thickness. Our default standard thickness is 1 5/16", but that can be varied from 7/8" to 2 1/4" to match existing exterior shutters. The length and height can be specified to the nearest 1/16" inch. Depending upon the style of the shutter, we have made widths up to 20 feet wide, and heights up 30 feet.
Because all of our exterior wooden shutters are custom built from true rail and stile construction, we have the ability to replicate any component dimension on existing shutters, including rail height, placement, width, thickness, and stile width and thickness. Typically, the bottom rail of our custom shutters is 4. high, and all other rails are 2 1/2" inches. Stile widths are usually 2 1/2" but we have the ability to make them of virtually any width, including different widths for left and right stiles -- sometimes used for pairs of shutters.
Out standard products are S4S, or square shoulder sticking, but we have the capability to mould any feasible profile to the inner or outer frame fields. Common choices are ogee, cove and bead, bevel, cove etc. In addition to our stock sticking profiles, we can also custom grind tooling to achieve any desired profile to either match historical wood shutters, or to meet an architects or home owner.s specifications and preferences.
For operable shutters, or for decoration, our wood shutters can be machined with a bead on one face of the inside edge of the shutter, and with a ship lap on the other, allowing the shutters to overlap by 3/8" when they are in the closed position - permitting a tighter fit. The left and right shutters are machined as pairs so that in the closed position, each face of the pair has a decorative bead visible.
Our raised panel shutters can be raised with our standard scoop profile, but we offer bevels, coves, ogeees and other profiles as well. Additionally, for the extremely discriminating home owner or architect we can create new tooling to match existing historical panel profiles, or to meet with a unique custom requirement.
Our louvered shutters can be fitted with either our standard bullnose louvers in 3 sizes, or with a chevron or bevel profile as options. And because we are a custom shutter maker, we can also accommodate any special profiles that are specified by the customer.
Raised Panel and Flat Panel Shutters can have a limitless variety of decorative cut outs machined into the center of the panels. Common shapes are moons, anchors, trees, hearts and we have a large number of stock cut outs which we offer, as well as the ability to match custom patterns that are provided by the customer
Estate Millwork can ship our custom wooden shutters in natural, primed, painted or stained finishes. We can match national brand color numbers, pre-tint primers for light or dark finishes, and apply hand rubbed stain finished, even to the time consuming louvered shutters.
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.
At Estate Millwork we air dry much of our lumber, and after air drying we finish drying in low wattage dehumidification kilns.
Every piece of wood we purchase is used to the fullest on products, at Estate Millwork we have a very high yield ratio of 94 percent due to the use of automated saws and optimizing software. The remainimg 6 percent which is mostly sawdust and chips are either burned to heat our plant or send to local cattle farmers for bedding and composting.
Nothing is wasted. Some of Appalachian lumber we use comes from Amish farmers in our county who harvest with horses instead of mechanized equipment, and do our rough sawing on 1920s sawmills that are also extremely low input compared to larger commercial sawmills of today. All of our imported lumber is plantation grown, and not harvested from natural forests.
To learn more about our sustainability practices click here
|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 5/16 "||Solid Wood||Rigid Integrity|
|Stile Width||2 1/2 "||Hand Jointed||Vertical Stability|
|Base Rail||4 "||Balance||Architecturally Correct|
|Crown Rail||2 1/2 "||Balance||Historically Accurate|
|Louvers||3/8 " X 1 3/4 "||Solid, Bullnose||Traditional Detail|
|Louver Pitch||-67.5 Degrees||Fixed Louvers||Sturdy, Air flow|
|Louver Spacing||1.375 "||Variable Options||Customizable|
|Applications||Built to your requirements|
|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.|