Premium High Quality Sapele Flat Panel Flat Panel Shutters
Exterior Wooden Flat Panel Shutters by Estate Millwork
Exterior flat panel shutters make a statement -- and your home deserves the elegance of timeless and durable Estate Millwork premium-quality exterior flat panel shutters. Our solid wood shutters are available in a wide variety of styles and materials, and will increase the distinction and charm of any home they adorn. Estate Millwork exterior shutters are crafted from sustainable-harvest top-grade hardwoods, then carefully dried and stored. At our eco-friendly wooden shutters plant, Estate Millwork controls quality every step of the way -- from tree to finished product.
Exterior Flat Panel Shutter Construction
The process of creating our durable and distinctive exterior shutters begins with the hand selection of rough wood stock. We start with top grades of hardwood (FAS, 2FAS and CLEAR) and hand-select each board. Our use of hardwoods distinguishes us from other manufactures that use soft wood such as western red cedar, incense cedar, or pine. By hand-selecting each board, we are able to minimize waste, maximize quality and provide our customers with extremely durable, solid wooden shutters that outlast the vinyl or low-grade veneer exterior shutters our competitors are selling. We even manufacture exterior shutters in exotic hardwoods such as mahogany and teak.
Customizing your Exterior Flat Panel Shutters
Estate Millwork's exterior shutters are all custom-built to your specifications. We use 18th-century mortise-and-tenon joinery methods in our state-of-the-art mill. Our solid wood exterior shutters can be constructed with operable louvers or fixed louvers in a variety of configurations, and can be crafted from various species of wood, including poplar, cherry, maple, cedar, mahogany, oak, and teak. A combination of modern automation and traditional craftsmanship allow us to produce the highest quality interior and exterior shutters on the market, while still offering competitive pricing.
Exterior Flat Panel Shutters with Old-World Craftsmanship
Once the lumber has been selected for your custom exterior shutters, it is processed in-house by our expert woodworkers. The rough lumber is transformed into finished dimensional lumber using computer software to maximize yield and quality. The dimensional lumber is then machined by precision CNC equipment (Editor's note: Much of our in-house equipment is designed by Estate Millwork employees.) which allows us to economically produce exterior shutters with minimal waste. The parts are then handed over to our talented craftsmen for final assembly. Each set of exterior shutters is machine-sanded, hand-finished, and optionally primed, painted, or stained to your specifications.
Exterior Flat Panel Shutters: Primary Benefits of Ordering from Estate Millwork
Exterior shutters milled from FAS premium hardwoods
Solid wood milling process ensures sturdy products
Energy efficient exterior shutters that dampen sound
Many priming and finishing options for exterior shutters
A wealth of customization options available
Fully customizable shutter louvers and fixtures
Top-quality customer service from our exterior shutter experts
Advantages of Estate Millwork Exterior Flat Panel Shutters
Our solid wooden exterior shutters are whole-cut from solid pieces of durable, top-grade lumber. Many of our competitors construct their exterior shutters from multiple pieces of wood. This type of construction results in inferior durability and energy efficiency. By contrast, our whole-milled exterior shutters offer incredible climate control for your home.
In addition to superior materials, our endless customization options ensure that you receive a superior-quality product that fits your home or condo perfectly.
Energy-efficient exterior shutters- Whole-cut solid wood is used in the milling of all of our exterior shutters. This ensures that there are no cracks, low-quality joins, thin filler wood, or other inferior milling techniques that can cause shutters to leak warm air in the winter or cool air in the summer. In addition, you have the option to customize your exterior shutters to fit your windows seamlessly for optimal energy efficiency.
Superior durability- Top quality, FAS premium-grade hard woods are used the milling of Estate Millwork exterior shutters. Choose from poplar wood, teak wood, mahogany wood, cherry wood, cedar wood, maple wood, and oak wood. Different wood types are suited for different climates and environments, so if you require help in choosing the wood best suited for your location call our shutter experts at [an error occurred while processing this directive] for assistance.
A full complement of customizations- Receive the exact shutters that you want: just use our online custom design tools, or speak with one of our customer service representatives. Select from custom mouldings, carvings, hardware, and more. We can also create exterior shutters from your AutoCAD or hand-drawn sketches. Our customizations assure that you receive elegant exterior shutters that suit your tastes and lifestyle perfectly.
Solid Wood Mortise and Tenons
True Tenons
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.
Deep Pocket Mortises
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.
Hardwood Dowels
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.
Hand Assembly
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.
Shutter Options
Thickness, Width, Height
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.
Shutter Frame Dimensions
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.
Custom Sticking
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.
Shiplapping and Beading
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.
Panel Profiles
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.
Louver Styles
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.
Cut Outs
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
Finishes
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.
Exquisite and Durable Sapele Hardwood: A Hidden Treasure
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
