Breakers Raised Panel Door

1

Breakers Raised Panel Door
Sapele Unfinished-Paint Grade
1 3/8" X 32 " X 80 " No Jamb

$1,434.10 Each.

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Premium High Quality Sapele Raised Panel Doors


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.

Exquisite Craftsmanship: Custom-Crafted Solid Oak Raised Panel Doors

Consider investing in an Estate Millwork all-wood custom oak door for a timeless addition to your home. Crafted with meticulous attention to detail and employing eco-friendly practices, each of our custom doors promises longevity and satisfaction for years to come.

Oak wood stands out for its enduring qualities. Renowned for its density, strength, and natural resistance to pests, oak is a hardwood that embodies longevity. Whether you prefer a stained, painted, or natural finish, our custom oak doors exude elegance, thanks to their versatile appearance. Crafted with precision, these raised panel doors are designed to withstand the test of time, ensuring that they remain a fixture in your home for decades.

When it comes to oak, you have choices. Available in red and white varieties, each with its distinct characteristics, oak offers versatility in design. While white oak boasts superior water resistance, red oak captivates with its warm, salmon-pink undertones, adding a touch of sophistication to any space. With oak's ease of manipulation, the possibilities for creating bespoke doors are virtually limitless, allowing you to tailor your doors to suit your unique preferences and style.

Discover the Excellence of Our Oak Doors and Sustainable Practices at Our Eco-Friendly Plant

As our planet faces increasing environmental challenges, Estate Millwork remains committed to minimizing the carbon footprint of our wood door manufacturing processes. We prioritize sustainability by sourcing our wood exclusively from providers committed to responsible harvesting practices. Moreover, our manufacturing plant operates with eco-conscious principles, implementing rigorous recycling measures and energy-saving techniques on a daily basis.

When it comes to the construction of your custom doors, authenticity is paramount. Unlike faux-wood alternatives that often pale in comparison, we pride ourselves on crafting each door with 100 percent genuine oak wood. Our team of door experts understands the inherent durability and timeless beauty of solid oak, ensuring that every custom door we produce reflects the highest standards of quality and craftsmanship.

At Estate Millwork, we select only the finest grades of red or white oak for our custom wood doors. By utilizing these premium materials, we guarantee that your doors not only meet but exceed your expectations for elegance, durability, and sustainability.

Enhance Your Home with Exquisite Raised Panel Oak Doors

Exterior Oak Doors: Harnessing the innate water-resistant properties and durability of oak, our custom-crafted exterior entry doors offer unparalleled quality and style. With a diverse range of oak door options available, choosing the perfect one may require a little extra consideration.

Interior Oak Wood Doors: Engineered to withstand the rigors of daily life, our solid oak interior doors are built to endure the demands of pets, children, and everyday use. With meticulous attention to detail and utilizing only the finest white or red oak materials, our expert craftsmen ensure that each custom wood door delivers exceptional longevity and enduring beauty.



Wooden Doors Fabricated from Premium Lumber Grades

Solid Wood Doors Built with Premium Grade Lumber

Stain Grade Lumber

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.

Paint Grade Lumber

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.

Color and Grain Matching

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.

Milling and Sawing Specifications

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.

Top Quality and Elegant Custom Wood Doors

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.

Hand Selection and Inspection of Materials

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.

Precision Ripping of Rails and Stiles

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".

Hand Jointing of All Door Components

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.

Precision moulding of all door components

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

Precision CNC Machining of Mortises, Tenons and Louver Slots

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.

Hand Assembly by Experienced Craftsmen

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.

Machine Sanding to tolerance

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.

Hand Sanding.

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.


Exquisite and Durable Sapele Hardwood: A Hidden Treasure

Sapele Wood Grain

Sapele lumber, sourced from the sapele tree native to the tropical regions of West Africa, stands as a prized gem in the realm of fine woodworking. Renowned for its stunning appearance, remarkable durability, and versatile nature, sapele wood is cherished by woodworkers and builders alike for its myriad of applications.

Often hailed as the "African mahogany," sapele hardwood boasts a captivating palette ranging from rich reddish-brown to deep mahogany, acquiring a luxurious patina with age that enhances its innate elegance. Its distinctive ribbon-like grain patterns and lustrous finish add an air of sophistication to any project, captivating designers and craftsmen seeking to create visually striking pieces.

Beyond its aesthetic allure, sapele hardwood offers exceptional durability, withstanding wear, decay, and rot with ease. Whether utilized for interior or exterior projects, sapele's stability and strength ensure longevity and functionality for generations to come.

Highly workable and responsive to finishing techniques, sapele hardwood lends itself to a myriad of design possibilities. Whether applying a clear finish to accentuate its rich grain or opting for a darker stain to infuse depth and character, sapele adapts effortlessly to achieve desired aesthetics. From fine furniture and cabinetry to boat building and musical instruments, sapele hardwood proves its versatility time and again, cementing its status as a valuable asset in the world of woodworking and interior design.

Handcrafted with Sustainably Harvested Lumber

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


MaterialSapelePremium FAS Clear GradeRot Resistant, Insect Resistant Premium Exterior Lumber
Joinery3/4" X 3"True Mortise & Tenon,Strongest solid wooden joint
Frame Thickness1 3/8 "Solid WoodRigid Integrity
Stile Width4 15/16 "Hand JointedVertical Stability
Base Rail7 15/16 "BalanceArchitecturally Correct
Crown Rail4 15/16 "BalanceHistorically Accurate
Raised Panels(1.375-.25) " ThickSpline Jointed, Grain Reversed 2 X the glue surface and strength
FinishMachine Sand 120, Hand Sanded 150Drum,Edge & Palm sandedTop quality hand finish
PackingFoam Wrapped in Custom Built Carton1/8" Foam, 3/16 Trim Sheet 100lbProtection against damage in transit.
QuantityDescriptionDimensionsMaterial
2Stile 1 3/8" X 4 15/16" X 80 " Sapele
1Rail 1 3/8" X 7 15/16" X 26 1/8" Sapele
1Rail 1 3/8" X 4 15/16" X 26 1/8" Sapele
5Raised 1 1/8" X 9 15/16" X 22 5/8" Sapele
10NorthMiter,SouthMiter 3 11/16" X 3 3/4" X 22 1/8" Sapele
10EastMiter,WestMiter 3 11/16" X 3 3/4" X 9 7/16" Sapele
4Rail 1 3/8" X 5 " X 26 1/8" Sapele
Raised Panel Doors Picture