Walnut exterior wooden shutter sets are an excellent choice for homeowners who are concerned with value and quality. Walnut is an exceptionally sturdy domestic hardwood with a handsome, chocolate-brown luster. Its strength makes it an optimal wooden shutter material.
Unlike competitors, our walnut wooden shutters are crafted from 100 percent genuine walnut wood. We refuse to offer our customers inferior products, and allow no plastic fillers or cheap, particle-board sections in our walnut exterior wood shutters. Each shutter set is made to ensure that you.ll enjoy a return on your investment for years to come.
At Estate Millwork, quality of craftsmanship is one primary concern. Environmental preservation is another. All of our domestic walnut wood vendors use green harvesting techniques. We strive to offer an environmentally friendly working environment at our shutter plant, too. All walnut shutter scraps are used in other projects or burned for fuel in the colder months. We also enforce strict temperature controls to save on fuel, while scheduling work shifts to ensure maximum worker health and productivity.
Beautiful hardwood: Walnut wood is a shutter material that's very pleasing to the eye. This hardwood ranges in color from pale cream-mocha to deep chocolate brown. Walnut's distinctive growth rings add character to the wood, and, when finished or stained, walnut shutters glow with a rich sheen.
Strength makes for sturdy shutters: Walnut wood is very dense and strong, making it perfect for shutters that must endure the elements. This is a highly workable wood, as well; its ability to be carved and shaped makes it a top choice for guitar bodies, shotguns, furniture, and flooring.
Each set of walnut exterior shutters is crafted using genuine walnut wood and sturdy mortise-and-tenon joinery.
Gorgeous, rugged walnut wood makes an attractive choice for your customized exterior shutter sets. An Estate Millwork telephone representative can help you customize your walnut shutters to suit your tastes.
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.
Walnut Hardwood Lumber is a premium domestic hardwood valued for its rich color and excellent finishing qualities. Walnut has a slightly open grain varying from wavy to irregular with an even and uniform medium to coarse texture. Walnut is a unique domestic species, because there are no other North American species of wood with the same distinct chocolate brown colored heartwood. The wood's rich tones make for excellent doors and paneling, and as a furniture wood, it is hard to beat.
Walnut gained popularity back when colonists started importing the lumber to Europe for furniture and interior woorwork, because it was so plentiful then it was easier and cheaper to obtain than Mahogany.
Today, Walnut is still highly prized for furniture and interior woodwork, but it is growing in popularity is starting to match that of Cherry. A significant development in the Walnut lumber use is in the marine industry, boat builders are now using the dark color on yacht interiors as a contrast to the lighter tones of Teak. At heart Walnut wood is a statement of luxury and is used in many applications to that effect.
Freshly milled Walnut can exhibit many different color hues, from deep browns and purples to light creams. Steaming Walnut will even out some of those color variations and creates a much more uniform and mellow chocolate color, over time and with oxidation and exposure to the sun Walnut will lighten in color and blends well with most other species.
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||WalnutMaterial||Walnutar Grade||Rot Resistant, Insect Resistant Premium Exterior Lumber|
|Joinery||3/4&quoJoinery||3/4&quoMortise & Tenon,||Strongest solid wooden joint|
|Frame Thickness||Frame Thickness||) "||Solid Wood||Rigid Integrity|
|Stile Width||FraStile Width||Fraquot||Hand Jointed||Vertical Stability|
|Base Rail||FractBase Rail||Fractance||Architecturally Correct|
|Crown Rail||FracCrown Rail||FracBalance||Historically Accurate|
|Louvers||FractioLouvers||Fractio1 3/4 "||Solid, Bullnose||Traditional Detail|
|Louver Pitch||-6Louver Pitch||-6d Louvers||Sturdy, Air flow|
|Louver Spacing||Louver Spacing||able Options||Customizable|
|Finish||Machine Finish||Machine anded 150||Drum,Edge & Palm sanded||Top quality hand finish|
|Packing||Foam WrPacking||Foam WrBuilt Carton||1/8" Foam, 3/16 Trim Sheet 100lb||Protection against damage in transit.|