If you're searching for the perfect addition to your home, consider Estate Millwork's custom cherry doors and custom entryways. Estate Millwork represents quality and customer satisfaction. Our expert craftsmen put the same love and care into each cherry door that 18th.century woodworkers did, while our Earth-friendly plant rises to the consumer challenges of the 21st century.
What's in a Custom Cherry Door?
Cherry doors look great: Cherry wood is native to North America, and is found chiefly in Mid-Atlantic forests. Cherry is best known for its richly textured wood grain and its glowing, deep-red hue. Whether stained or left natural, our cherry louvered doors suit a variety of architectural styles.
Cherry doors hold up: Early American furniture was often made of cherry because this wood shows excellent density and strength. Because cherry wood is also highly workable, it is an especially suitable material for custom doors, including exterior wooden pieces.
Custom cherry wood doors from Estate Millwork: a wise investment
Unlike the competition, every single custom door we manufacture is created only from the finest pure cherry wood. While inferior particle-board or veneer doors warp or weather poorly, our doors last. Genuine, tight-crafted mortise-and-tenon joinery, double-tongued and feather-tenoned base rails, and solid, pure cherry hardwood components mean our doors are the real thing.
Quality products aren.t our only concern at Estate Millwork. We are also deeply committed to environmental sustainability. We partner with green-harvest suppliers for each and every piece of cherry wood that goes into our custom cherry doors. We.ve also implemented temperature controls, recycling programs, and strategic scheduling of work shifts at our door-making headquarters.
Choose from Custom Cherry Interior Doors or All-Wood Outdoor Entryways
Exterior Cherry Wooden Doors:
Cherry wood is naturally decay resistant. It's an excellent choice for any wood door or entryway that must endure the elements. Whether you live in snowy New Hampshire or sunny South Carolina, our custom cherry entryways withstand the weather.
Interior Cherry Doors:
If you order a custom cherry interior door from Estate Millwork, rest assured that your door will be put to the test. Whether you have kids, pets, or a physically vigorous partner or relative, your door will need to be strong and sturdy. Estate Millwork uses real wood in all of our cherry doors; it's the plain-as-day secret to our success.
Our custom cherry doors are made from 100 percent genuine, top-grade hardwood.
Not Sure Which Custom Cherry Wood Door is for You? Browse Several Styles:
Louvered Cherry Doors:
Louvered cherry wood doors work well inside or outside. This door style, which consists of thin wooden slats set inside a cherry frame, is a perfect climate-control aid. Enjoy the breeze . and lower air-conditioning bills . with a cherry louvered door.
Raised Panel and Flat Panel Cherry Wood Doors:
These cherry wooden door styles, which consist of raised or flat cherry wood panels set inside strong frames, provide you with endless customization options. Choose from a variety of popular styles, including the classic 8-panel Georgian James Adams and the stately 3-panel Georgian Salisbury.
True Divided Light Cherry Wooden Doors:
If your home could use a lighting boost, consider a true divided light custom door. We have several versions of this style, which consists of many small panes of glass set inside sturdy cherry muntins (grilles). Choose from a variety of French styles, including the Louis XVI and the Antoinette, or create your own custom cherry door.
Mission Style Cherry Custom Doors:
Period purists might recognize the mission -style cherry door from post-World War II American architecture. This distinctive, paneled wood door style is perfect for people who love the .classics. and for people who desire customization.
Estate Millwork's custom cherry wood doors and entryways are built to last. To learn more about our fine cherry wood products, contact us today.
Louvered Pocket Doors are an Elegant Way to Divide Living Spaces
Louvered Doors can be ordered in a sliding or bypass configuration for closets or rooms whereby the louvered door is received by an opening in the wall, either on one or both sides of the opening. Commonly used for larger doors that partition walk-in closets, rooms, or living spaces, pocket doors are a very convenient way to quickly separate or unify spaces. When open, the doors are not visible. Probably the most complicated method for installation, it often requires pre-planning, for the removal of studs and the addition of headers, and it is most economically done in new construction. However, it is a very common application in well-built older homes as well, and Estate Millwork can exactly match your existing pocket doors if they need to be replaced, or to be used in a remodeling.
Precision Crafted Louvered Doors Using State of the Art CNC Machinery
Solid Louvers
Each louver in our louvered doors 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 door is to use fixed louvers or operable louvers, we can even create custom tooling to match existing millwork or to provide the ultimate in personalization and detailing.
True Louvered Door Mortises and Louver Mortises
Each louver in a fixed louvered door is seated in a 7/16" deep mortise in the door stile. Our CNC machining equipment can 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 doors to a precise specification in terms of louver count, rail placement, and airflow. In the same pass as the louver mortises are being created, our equipment also creates the larger mortises for each rail in the door. Unlike many custom door 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 door manufacturers as too expensive. Because we have invested heavily in automation, our cost to produce highly custom louvered doors using solid materials and premium joinery is much lower than other manufacturers, hence: higher quality, lower price.
Solid Tenons
The tenons on both ends of each rail are engineered to give maximum stability to the louvered door frame, and when combined with our hardwood doweling, the door frame will stay together and be extremely stable, even without glue. But of course we use glue for added strength. For larger louvered doors, 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 proprietary 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.
Wooden Doors Fabricated from Premium Lumber Grades
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.
Cherry: A Luxurious Hardwood with Timeless Beauty
Hailing from the pristine Appalachian region of the United States, Cherry wood stands as a quintessential domestic hardwood renowned for its exquisite beauty and exceptional working properties. Characterized by its luscious, rich color and fine, uniform texture, Cherry wood boasts a striking reddish-brown hue, occasionally punctuated by charming gum spots. The heartwood of Cherry is notably robust, exhibiting commendable resistance to decay, making it a favored choice for a myriad of interior applications including doors, windows, moldings, and, particularly, furniture.
While Cherry's initial appearance may surprise some, with rough sawn lumber presenting a lighter pink hue, its true beauty unfolds over time. Through exposure to UV rays and natural oxidation, Cherry wood matures into a sumptuous brownish-red, epitomizing its inherent allure. Some enthusiasts hasten this transformative process by subjecting their Cherry lumber to sunlight, while others opt for dyes or stains to achieve desired hues. This "breaking in" period is crucial to consider, especially in restoration endeavors aiming to match existing trim or furniture.
Cherry hardwood remains a timeless and opulent choice for woodworking and interior design ventures, cherished for its unparalleled beauty and versatility. Our meticulously sourced Cherry hardwood is expertly crafted to uphold uncompromising quality standards. Infused with rich, reddish-brown tones and distinctive grain patterns, Cherry wood exudes a warmth and sophistication that transcends trends. Whether crafting bespoke cabinetry, refined furniture pieces, or resplendent flooring, Cherry hardwood imparts a touch of elegance that endures through generations. Not merely a feast for the eyes, Cherry hardwood is celebrated for its enduring strength and durability, ensuring a legacy of enduring beauty for years to come.
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
