Looking for a fresh twist for a tired home? Select one of Estate Millwork.s teak wood door styles, or design your own custom teak door or entryway. Our reputation for genuine wood craftsmanship and our Earth-friendly business habits mean that our doors and other custom teak products are unsurpassed.
Two reasons why teak wood doors are tops:
Teak wood doors last: Natural teak wood is durable, weathers well, and is especially resistant to termites and splitting. No matter which shape or style you choose for your custom teak wood doors, you.re sure to enjoy our creations for years to come.
Teak wood doors are good-looking: Indoor teak custom doors will retain the rich golden color of freshly harvested teak wood. Teak exterior custom entryways will take on a smart, silver-golden tone. Preserve your wooden doors with teak oil for an extra-rich finish.
Custom teak wood doors from Estate Millwork: Earth-friendly strength
Estate Millwork values conservation and green engineering. Therefore, we only do business with teak importers who use green harvesting techniques. We also practice energy-conservation techniques every day at our door manufacturing plant, and enforce teak wood reuse and recycling practices.
Part of our mission to reduce waste involves using only the best genuine teak wood in all of our custom doors and custom entryways. We would be cheating our customers if we sold anything inferior, like particle-board panels or faux-wood synthetics. If doors aren.t durable, they.re relegated to landfills. By contrast, our custom teak wood doors will grace your home for years to come.
We use genuine teak wood, with no artificial fillers, in all of our custom teak doors and entryways.
Inside or outside, our teak wood doors endure
Exterior teak wood doors:
Teak wood is a top choice for exterior doors located in termite- or rough-weather-prone areas. Teak.s natural strength and density and its high level of workability mean that a variety of long-lasting custom entryway styles and sizes are completely possible.
Interior teak wood doors:
Teak custom doors should be built to withstand outdoor and indoor conditions. Kids, pets, houseguests, and foot traffic can all contribute to a door.s aging. Fortunately, our custom teak interior wooden doors are crafted entirely of genuine teak wood, so they might just outlast your house.
Choose from many smart styles of custom teak wood doors and entryways:
True divided light teak doors:
"True divided light" is a fancy term for custom doors that feature many small glass panes set inside muntins (grilles). Each custom teak wood door or custom entryway is crafted with the care commonly attributed to the Estate Millwork name. To enjoy a beautiful display of light, consider our true light custom teak wood doors.
Mission style teak wood doors:
Mission-style custom teak doors are most commonly seen in mid-20th century architecture. This pleasing style, which consists of varying sizes of horizontal wooden slats nestled inside a solid teak frame, is highly customizable, and suitably fulfills your interior door or custom entryway requirements.
Louvered custom teak doors:
Louvered teak custom doors and custom entryways foster excellent air flow between rooms, or between the inside and outside of your home. We guarantee that each louvered custom teak door is made from real wood, using top-quality craftsmanship.
Flat panel and raised panel teak doors:
Estate Millwork flat panel teak doors and raised panel teak doors are completely customizable, and all are constructed from 100 percent real teak wood. Some popular styles of panel doors include the Early American Jefferson flat-panel door and the Georgian Bolton Abbey door.
Your new teak custom door or custom entryway is a phone call away. Get in touch with one of Estate Millwork.s door experts, and add a new dimension to your home.
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.
Teak: The Exquisite and Highly Valued Golden-Brown Hardwood
Teak wood's allure lies in its captivating golden-brown hue, a characteristic that has long made it a prized choice for artisans and craftsmen. When freshly machined, teak may exhibit a variable pattern, but with exposure to sunlight and air, its streaks gradually mellow into the signature golden-brown appearance that defines its beauty and value.
Growing in sandy soils, teak boasts a naturally high silica content that permeates its fibers, rendering it nearly impervious to water. Additionally, the wood's inherent oils serve as natural insect repellents, enhancing its durability and resilience. Once milled, teak maintains its shape exceptionally well, making it a preferred material for yacht builders and other craftsmen working in demanding environments requiring precise tolerances.
While teak's resin and oil content contribute to its outstanding exterior performance, they also give rise to dramatic color variations when freshly planed or cut. Striking hues of grey, green, and orange, along with harsh streaks, may initially appear, temporarily obscuring the prized honey-brown color. However, it's crucial to recognize that these variations will gradually fade over time, allowing teak's signature golden-brown hue to emerge and deepen, further enhancing its timeless beauty and allure.
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
