The Foundation: Selecting the Right Timber

The process starts with meticulous selection of wood. Popular choices for doors include pine, oak, cherry, mahogany, and maple, each offering unique aesthetics and properties. Plywood doors utilize thin layers of wood veneer, ensuring strength while optimizing resource usage.

Shaping the Vision: Cutting and Prepping the Wood

Skilled artisans meticulously cut the chosen wood into precise shapes based on the door design. Saws, routers, and other cutting tools transform raw timber into the building blocks of the final product.

Strength in Layers: Crafting the Plywood Core

For plywood doors, thin wood veneers become a symphony of strength. Each layer is meticulously glued with its grain running perpendicular to the adjacent layer, creating a cross-grain structure that boasts exceptional stability and resistance to warping. High pressure presses then forge these layers into a solid and robust panel.

Building the Frame: The Door’s Skeleton Takes Shape

The door’s skeletal frame takes form by joining stiles (vertical components) and rails (horizontal components). This framework provides crucial support and structure for the entire door. To further enhance the visual appeal, decorative moldings can be added during this stage.

Panel Integration: Adding Depth and Design (for paneled doors only)

If the door design incorporates panels, carefully selected pieces (solid wood, plywood, or other materials) are meticulously inserted into the pre-built frame. These panels contribute not only to aesthetics but can also offer additional soundproofing or insulation qualities.