Building a door is difficult; and building a door of precision and high quality is a real challenge.
Production line doors are not infallible, and use average glues, average woods, average finishes and perhaps will look good for a while; but often fail after just a few years with finishes that fade or expansion resulting in blowing out of the bottom of the door.
We use specialized processes to built the door that would be impossible in an environment that requires doors to be built in just a few days.
Specifically we address types of doors differently and here is how:
Hinges & Hardware
We use Hager ball bearing hinges with higher load ratings than most. For Concealed hinges we use Tectus hinges from Germany. The hinges we place on our doors are several times stronger than most hinges provided by door makers.
The door hardware we use is sourced for each job based on the desired look and there is a near infinite selection from fingerprint readers, handles, door pulls and levers.
A true wood finish without colored stain. When you see our doors with Walnut, what you are seeing is true Walnut without stain. Quality woods only require a clear coat to bring the richness out; whereas a wood requiring coloring stain is not of the real quality and inevitably the color stain will fade revealing a patchy wood beneath.
All our doors that reveal a true wood finish are either finished in lacquer for interior doors; and for exterior doors we use a multiple finishing system of Waterlox that provides a waterproof barrier that is easy to maintain and is often the choice of boat builders. We will also use varnish where appropriate.
Where a door is to be painted we provide a superior door to others. First, a specialized 2-part glue is used to attach a wood veneer to the core of the door. This in itself is waterproof, but to ensure no possibility of the core being compromised we also coat the entire door, all routed out holes and hardware intrusion points with a marine grade epoxy. This epoxy has an indefinite lifespan. Only after the above 2 week process do we then paint the doors.
The Door Core
While much fuss can be made as to which core is better, the reality is that all cores will only hold up as well as the materials surrounding the core. For this reason the veneers we apply over the cores are the key to making a quality door. All 6 sides of the door are seen to - not just the front and back. Possibly the most important failure point of a door is the bottom facet - often ignored by builders- yet most door failures arise from unfinished and improperly sealed bottoms. We apply epoxy, wood then epoxy again to the bottom and it is not expected to ever result in a failure.
We use stainless steel and brass on our doors - not toned to be like these materials but actual true solid brass or stainless steel is used. Our brass for interior use is coated to keep it bright, and our exterior brass will patina over time - no finish can be applied to exterior brass that lasts a sufficient time and often those coatings that have limited life and we will use them if requested but do not warranty the finish on the brass for more than 3 years.
Each of our sunburst or starburst designs is finished with a brushed finish and each bar is machined by hand - there are no two doors with the exact same lengths.
A custom door should be a work of art, unique in itself and precisely made for a setting. And it should last.
For a residence in Stamford, CT. Special walnut with solid brass relief on both sides. 85" tall and 45" wide. Waterlox finish.
At 118" tall and 50" wide, this entry door for a residence in NC required a special construction for the door in order to guarantee it could not warp. Complete with fingerprint ID pad inset in the handle. Specialized epoxy coating over walnut.
Built for a client in California, these doors were fire-rated and have solid bars of aluminum over both sides with a brushed finish. Completed in a custom white color to match the client's interiors.
Steel was the choice for this door over a blue specified by the customer for a residence in
Palm springs. The next image shows the interior in a different color.
The client required a 2-color door and here in the interior in white.
Produced for a client in Michigan, these doors invite whiplash from a thousand yards.
If customers can’t find it, it doesn’t exist. Clearly list and describe the services you offer. Also, be sure to showcase a premium service.
Each bar of architecturally graded brass is individually cut and finished with smooth edges and a meticulous brushed finish before a protective coat of clear is applied.
Sunburst or starburst? Each door has each bar in different lengths to suit the knob or handle position as well as the width of the door. No two doors are ever the same.
Brass and black are amazing bed fellows for design, providing a sleek look that is bespoke.
Marine aluminum over Walnut featuring a large crescent handle for a fine Mid-Century home in North Carolina.
Large starburst in solid brass that moves with the panels on this 20 foot garage. It now becomes a design highlight of the home to visitors and to yourself every day as you come home.
Brass bar over black lacquer for Interior Master Bedroom.