Door Construction

  1. Epoxy

A two part exterior epoxy adhesive for wood is used for all gluing during the door construction.

  1. Core

More time is spent on the construction of our door cores than some companies spend building an entire door. Stiles on all doors, and sometimes rails, are built using a maple core. The core is glued together using approximately twenty five pieces, each piece is ¾” x 1 ½” x 24”, laid out with staggered seams. All ends are glued to prevent water wicking inward. After three days of drying the core stock is joined flat, planed to size, sanded smooth with 60 grit and then epoxied to matching edges(Oak, Mahogany…). A final rail core is 1 ¾” x 6” x 9’.

  1. Skins

Matching lumber boards (oak, mahogany…) are sawn in half and sanded to ¼” thickness and epoxied to the core. This creates a vapor barrier that surrounds the core, which makes the rail extremely stable. The finished skins (after the door has been completely sanded) are approximately 3/16” of solid wood. A solid wood skin allows you to sand out any scratches or dents that may occur over time. Using this method we are able to make a door with two different species of wood (oak on one side, cherry on the other side),and still maintain stability.

  1. Joinery

There are two major types of joinery:
Mortise and Tendon: A 2 ½” depth pocket is mortised into the stile. A 2 ½” tendon is cut onto the cross rails. Both pieces are epoxied and assembled together.
Cope Cut/Tongue& Groove: This joint has a ½” to ¾” tongue, which fits into a groove (not a deep pocket). This joint will fail over time; therefore it requires the use of 5/8” dowel pins to strengthen the joint. We epoxy the full dowel pins.

  1. Exterior Panel

Our raised panel is a three layer construction, two pieces of wood and one piece of 1/16” to 1/8” birch plywood. The layers are glued together with epoxy. This prevents the panel from splitting though in the event that the exterior finish is not properly maintained.

  1. Finish Sanding

After the door has been sanded, the entire door is run through a 42” wide belt sander at 60, 80 and 100 grit on each side and sanded down to 1 ¾” or 2 ¼”. At this point some manufactures are “finished”, but the door is still covered with cross grain scratches which will show up when the door is stained. Additional time is spent sanding each door with a half sheet vibration sander and using cross lighting to check the surface for scratches. The door is only finished when all scratches have been sanded out.

Additional Door Constuction Images