Fine Millwork. 100% American Made with Pride in Pennsylvania's Allegheny Mountains412.641.0177
Estate Millwork's wood doors are milled from the highest grades of wood and crafted using classic, centuries old techniques. All of our wood doors can be fully custom built to fit your home or business. Additionally, we can create a door that matches your dream door perfectly by providing multiple accent customization options or even milling a custom wood door from your original sketches. In the paragraphs below, we will explore our door making process and discuss what the advantages of our louvered doors are.
We offer customization for our interior and exterior doors. There are many ways to customize your doors and you can choose your specific level of customization. We offer a wide variety of pre designed styles to choose from. Perhaps you will find exactly what you are looking for in one of these designs. If not, you can take one of these base designs and customize from there. You can customize the fixtures, panel styles and sizes, width, height, wood type, stain or paint color, and more. This ensures that not only do you have a wood door that fits in fit your entryway exactly, it will also match the decor and style of your home. If you would like an even higher level of customization, you draw or sketch out what you want. We will take those sketches and create a custom rendering that we can use to mill your custom wood doors. Is this too much customization for you? Don't worry! You can work our team of experts that will help you design your custom wood doors at [an error occurred while processing this directive] to speak to a custom louvered door specialist. They will guide you through your options and help you choose the wood doors that will best suit your home. They will also help you select the type of wood that is best suited for your climate. If you would like to customize your wood doors online, we can help with that as well.
All of our woods that go in to our doors are hand selected from rough cut whole wood to ensure that you receive matching grains of wood on all of the components of your doors. We harvest all of our timber using sustainable forestry from local woodlands in the Alleghenies. These cuts of wood are hand selected by our mill working experts. Through a modern, hybridized process, we fuse old world techniques from the 18th century with modern automation to produce wood doors that are the most durable and best constructed on the market.Our milling process ensures the highest control of quality, moisture content, fresh surfaces for glue and climate control.
Both our exterior wood doors and interior wood doors are ensured to be the highest quality due to their hand-crafted construction, deep pocket mortise and tenon joinery, feather tenoned and double tongued base rails, floating panel frames, secure seated louvers, full custom thickness and sizing, historically accurate designs and styles, and are 100% American made.
Your wood doors can also be customized by color or stain. We offer exact color matching if you would like your wood door painted. We also offer a large variety of stains and finishes that will protect your doors and offer the perfect look to compliment your home or office.
Our wood doors ar far superior to the competition because we provide a level of attention to detail and customization that can't be matched. Our mill workers are all highly experienced professionals that have years of experience in milling custom wood doors, and in some cases our mill technicians are second or third generation mill workers. Our woods are the highest grade, premium, FAS approved hardwoods.
Energy Efficient Wood Doors - Whole cut solid wood is used to fabricate all of our wooden doors. Because the wood is solid and custom milled to the exact size of your doorway, you will have completely flush doors for your entryway. The solid wood will act as insulation to keep the internal climate of your home steady.
High Durability - High quality solid wood doors will last for decades if properly maintained. They can be repainted and restained if they show ware, and our wide variety of wood stocks ensures that you will be able to select the wood that is best suited for your climate and location.
If you have any questions about our wood doors or need help designing a custom wood door, please call [an error occurred while processing this directive] and one of our custom wood door specialists will help you for free with no obligation!
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.
When Mahogany first became popular in the western world, it was exclusively sourced Central and South America, but as supply began to dwindle due to poor logging practices, manufacturers began to search for alternatives. Today we find Mahogany still as a primary species used in fine furniture making but also so much more. Mahogany is a great exterior wood option as it is much lighter weight than many of its comtemport counterparts. Its stability makes it a great option for windows and doors and the clear quality and easy workability of the species makes for outstanding millwork where find details are needed.
Mahogany is an outstanding wood to work with and has experienced recent popularity as an exterior wood, it is used extensively by window and door manufacturers due to its exceptional moisture and rot resistance. Many cabinet and furniture makers prize the wood not only for its durability, but also for its ease of machining and its deep, rich color. As it was hundreds of years ago Mahogany still remains a hallmark of fine work.
Mahogany hardwood is synonymous with timeless elegance, renowned for its rich, reddish-brown color, exquisite grain patterns, and exceptional durability. One of the hallmarks of mahogany hardwood is its captivating appearance. Its deep, lustrous color matures beautifully over time, developing a luxurious patina that enhances its natural beauty. Whether you're crafting exquisite furniture, creating custom cabinetry, or installing flooring, mahogany hardwood adds a touch of opulence to any space. Beyond its aesthetic appeal, mahogany hardwood is celebrated for its durability and stability. It is known for its resistance to warping and shrinking, making it an excellent choice for high-end, long-lasting projects. Its fine, straight grain and smooth texture lend themselves to precision work, making it a favorite among woodworkers and craftsmen. Moreover, mahogany hardwood is highly versatile when it comes to finishing. It accepts stains and finishes exceptionally well, allowing you to achieve the exact look you desire, from a deep, traditional finish to a more contemporary and sleek appearance.
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||Mahogany||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 3/4 "||Solid Wood||Rigid Integrity|
|Stile Width||5 "||Hand Jointed||Vertical Stability|
|Base Rail||10 "||Balance||Architecturally Correct|
|Crown Rail||5 "||Balance||Historically Accurate|
|Flat Panels||.75 " Thick||Spline Jointed, Grain Reversed||2 X the glue surface and strength|
|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.|
|2||Stile.Left,Stile.Right||1 3/4" X 5" X 80"||Mahogany|
|1||Rail.Base||1 3/4" X 10" X 26"||Mahogany|
|2||Rail.Crown,Rail.Dividing||1 3/4" X 5" X 26"||Mahogany|
|2||FlatPanel.FlatPanel||3/4" X 22 1/2" X 30 1/2"||Mahogany|