Fine Millwork. 100% American Made with Pride in Pennsylvania's Allegheny Mountains412.641.0177
When it comes to enhancing the elegance and charm of your home or office, premium wooden raised panel doors are a timeless choice that exudes sophistication and craftsmanship. In this article, we'll explore the world of premium wooden raised panel doors, highlighting their unique features, benefits, and how they can transform your living or working space.
Exquisite Craftsmanship: Premium wooden raised panel doors are a testament to the artistry and skill that goes into their creation. Crafted from high-quality wood, such as oak, maple, or cherry, these doors showcase the natural beauty of wood grains and intricate detailing. The raised panels add depth and dimension, making them a striking focal point in any room.
Elegance and Versatility: These doors are not only functional but also highly versatile in terms of design. They seamlessly complement various architectural styles, from traditional to transitional and even modern. Whether you're aiming for a classic look or a contemporary feel, premium wooden raised panel doors offer a timeless elegance that suits any interior.
Strength and Durability: Investing in premium wooden raised panel doors is an investment in durability and longevity. The solid construction and high-quality wood used ensure that these doors can withstand the test of time. With proper care and maintenance, they continue to showcase their beauty and functionality for generations.
Customization Options: Your design preferences are unique, and your doors should reflect that. Premium wooden raised panel doors come with a wide range of customization options, including wood finishes, stains, and hardware choices. This flexibility allows you to tailor these doors to your specific aesthetic vision.
Energy Efficiency: In addition to their aesthetic appeal, premium wooden raised panel doors can contribute to energy efficiency in your space. The solid wood construction provides excellent insulation, helping to maintain a comfortable temperature indoors. This can lead to energy savings and a more eco-friendly living or working environment.
Easy Maintenance: Maintaining the beauty of your premium wooden raised panel doors is hassle-free. Regular cleaning and occasional refinishing are usually all that's needed to preserve their exquisite appearance. The durability of these doors means they are less susceptible to wear and tear, making them a practical and low-maintenance choice.
If you're in the market for a time-tested classic, consider an Estate Millwork all-wood custom oak door. Our careful, skilled craftsmanship and cutting-edge green plant practices ensure that each custom door we sell provides you with years of satisfaction.
Oak wood is everlasting: Oak is a highly dense hardwood that is also strong, easy to work with, and pest-resistant. Our custom oak doors look classy stained, painted, or left natural; and quality craftsmanship ensures that you'll enjoy your louvered doors for decades.
Options: Oak wood comes in two varieties: red and white. While white oak is a bit more water-resistant than its cousin, red oak adds panache because of its creamy, salmon-pink hue. Oak is also easy to work with, offering endless options for custom doors.
Man's carbon footprint is growing. At Estate Millwork, we aim to reduce the impact our wood door manufacturing processes have on the Earth. Our supplies are green because we only partner with sustainable-harvest wood providers. Our plant is green, too: we practice recycling and energy-saving procedures each and every day.
No matter which style of door suits your tastes, rest assured that your custom door will be made of 100 percent real oak wood. Our door experts have seen firsthand just how poorly faux-wood furnishings hold up, and we guarantee that only solid oak components go into every custom door.
We use top-grade red or white oak in all of our custom wood doors.
Exterior Oak Doors: Oak's natural water resistance and strength mean it is an excellent material from which to fashion a custom exterior entryway. We offer so many kinds of oak exterior doors that you might just have to take some extra time to decide on one.
Interior oak wood doors: Strong, solid oak wood doors stand up to puppies, kids, cats, foot traffic, and frequent open-and-shut motions. By insisting upon expert craftsmanship and genuine white or red oak components, we create custom wood doors that last for years and years.
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.
White Oak stands as a remarkable domestic hardwood, prized for its widespread availability and affordability without compromising on quality. With its inherent strength and remarkably straight grain, white oak proves itself to be a versatile and easy-to-work-with material, ideal for crafting furniture, cabinets, and wider panels with seamless matching.
What truly sets White Oak apart is its captivating medullary rays, which become strikingly visible when the wood is quartersawn, adding a touch of elegance and character to any project. Once favored during the arts and crafts movement of the early 1900s, White Oak continues to be a preferred choice for furniture building, while its applications have expanded to include a myriad of uses in modern design and construction.
Beyond its aesthetic appeal, White Oak's unique cellular structure lends it exceptional water resistance, making it a preferred option for exterior applications ranging from trim and construction to garden structures. While its appearance may seem unremarkable at first glance, White Oak's true beauty shines through during the finishing process, allowing its natural charm to emerge.
Scientifically known as Quercus alba, White Oak boasts a pale, creamy color with grain patterns characterized by straight lines and distinctive ray flecks, adding to its timeless allure. Whether used for custom cabinetry, hardwood flooring, or refined furniture, White Oak brings a touch of classic elegance to every project. Renowned for its durability and resistance to wear, decay, and rot, White Oak ensures that your investment will withstand the test of time, promising lasting beauty and functionality for generations to come.
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 "
|7 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 7 15/16" X 26 1/8"
|1 3/8" X 4 15/16" X 26 1/8"
|11/16" X 9 15/16" X 22 5/8"
|1 3/8" X 5" X 26 1/8"