Custom Doors Built Strong
This big mahogany door is a great example of what can be done in a custom wood shop. We can create truly superior products in our own one-at-a-time way.
Better Wood, Better Construction
For one thing the frames of our doors are doweled together at every joint. This is, we believe, the strongest way to build a door.
Plus, if you are building your own door you can construct it out of better wood species and cuts of wood. We often use quarter sawn African mahogany. Quarter sawn wood is far more dimensionally stable than the plain sawn wood in most factory built doors. Mahogany in itself, is also more likely to lay flat and be stable than other woods.
We also laminate our door rails and panels with two layers of wood to, once again, make sure that the doors never warp or twist. It is kind of a big deal if your new custom door, for which you have paid substantial money, warps after you get it. It’s our job to make sure that doesn’t happen.
Door Thickness and Strength are Important
Other things to keep in mind when ordering a custom door are the thickness and strength of the door and frame.
Thick Doors Make Strong Doors
Once we decided to laminate two layers of wood on every door rail we found we could also build the doors thicker (meaning stronger) than typical factory doors. We suggest building doors to full 2” or 2-1/4” thick. This makes a much heavier, stronger door. It also makes a more beautiful one. All of the details are heavier, thicker, and show the door to have real substance.
Strong Construction is Our Jamb 🙂
The jambs as well should be considered for their safe, strong performance. A typical factory door jamb will be only pine and around ¾” thick plus the stop. I like to build door jambs at least 1-1/2” thick or more plus the stop.
This strength of frame is useful for resisting break-ins. It also assists in keeping a heavy door hanging straight for the long haul. When we see people on TV smashing in a door with a single kick or shoulder block – those are the cheap pine jambs from the big manufacturers splintering open. If the door and jamb are made from solid hardwoods in thicker dimensions, then that break in guy just bounces off. OK, even a great custom door and frame will, likely, not keep out the US Marshals. But any local thieves have at it cause you aint gettin in.
Those Lovely Ball Bearing Hinges
One last thing; heavy doors swing like a dream on ball bearing hinges. For heavy doors we typically use four, 5”, ball bearing hinges. You do not want to cheap out on the hinges. If the hinges are under sized you will have many difficulties keeping that door hanging straight and swinging properly.