1. Door preparation
Assembled doors pass through a strict quality control process prior to finishing which include both visual and physical tests. Any nail holes and leaks will be filled by oil putty.
2. Hand sanding unfinished door
Our doors are hand sanded using a series of paper grits to attain a smooth surface. All sanded doors will pass through our ultraviolet room where special lighting is used to detect glue remnants that might remain on the lumber after the sanding process. Excessive glue will cause adhesion problems and could lead to flaking.
3. The first coat of spray stain
Our doors then enter a spray stain booth where the first coat of stain is applied to the doors to an even finish.
4. Transparent polyurethane sealer
A coating of polyurethane sealer is applied to lock down the contrasting color stains and provide the first level of protection to the doors.
5. Glaze application and removal
Next, glazes are applied to all parts of doors to give them a rich and antiquated appearance. Our painting crafts then hand rub glazes between the moldings and panels which highlights these areas. The glazes are then removed from areas in which glazes remain.
Carefully airbrushes areas of the door needed to tone out any visual defects that might be present. Part of the objective is to even out the overall appearance of the door.
7. First priming, Polyurethane
The first priming of polyurethane is applied to provide the first protection which also helps to fill in the wood?s open grain pores.
8. Hand Sanding
After the first priming has dried, doors are carefully sanded to further close the wood’s natural pores. This process of sanding will knock down any remaining wood fibers while facilitating proper adhesion for the glazes, as well as the topcoats that will follow.
9. Second priming, Polyurethane
After the primed door is hand-sanded, another coat of polyurethane is then applied to provide further protection to our doors.
10. Hand Sanding
Hand sanding the whole door again for top coating.
11. Hand Sprayed Dye Stains
Next a contrasting dye is lightly applied to give depth the finish to create a rich appearance.
12. Hand Rubbed Smooth Finish
All doors are once again carefully rubbed down by hand to insure a smooth and even surface for final top coating.
13. Glaze Toning
Well trained crafts re-add and remove additional glazes to certain areas to get a naturally antiquated finishing.
14. First Coat, Polyurethane Finish
A top coat of polyurethane is then applied to lock in the glazes and provide further protection.
15. Second Coat, Polyurethane Finish
A second layer of topcoat is then immediately applied to provide the strongest protection available.