Cardinal solid oak custom made doors are something really special. Hand made to a full 44mm thickness and available either with or without a glass opening. Each door is made to your exact size requirements by our skilled team in our Sheffield factory.
The doors are manufactured to a 44mm thickness for a solid heavy door. The stiles and rails are made by laminating together two 22mm sections of solid oak. Laminating the sections in this way makes the door much more structurally stable than using a single piece of oak. All laminations are done in house so that we can control the quality. Each door is supplied with an oak weather bar which can be fitted on site.
We use mortice and tenon joints, which are wedged and hydraulically pressed to make the main frame of the door. This is a traditional method which results in a much stronger construction than the more common dowelled joints and means you can be sure your door is made to last.
Where a glass opening is specified this is made to the width of the internal panel. The opening is rebated to suit a 20mm thick sealed unit (4-12-4), and solid oak glazing beads are supplied with the door.
We manufacture exterior Cardinal doors using a specially selected grade of oak. The oak is bought directly from a number of partner sawmill in central and northern France where the best quality slower grown oak is found.
Most boards will be clear, some may have the occasional small knot emphasising the solid oak construction of these doors. There can be some colour variation within the boards as you find in any natural raw material.
All of our Oak is specially kiln dried to 8-10% for use as an exterior door and will exhibit minimum movement in use. As with all timber its extremely important to thoroughly finished external doors as soon as they are installed to prevent rapid moisture content changes that can lead to door swelling.
Standard and Custom Sizes
Cardinal external oak doors are manufactured to order to your exact size. We will make your door in any size up to 950mm x 2100mm for the same price. We can make larger doors but please call with your requirements for us to quote a price.
All the doors are made to a standard 44mm thick using laminated oak stiles and rails. To manufacture these we laminate 2 x 22mm oak sections in house.
We strongly recommend you specify the door a few mm oversize, and plane the door on site to suit unless you are absolutely sure that the door frame is 100% square. They rarely are! Your new oak door is custom made, and cannot be returned/refunded once manufactured so please consider these measurements carefully. We will confirm them back to you once you have let us know in an order confirmation so we both have a clear understanding of the size required
Please note that your new door is hand made and will take around 2-3 weeks to manufacture.
We do not offer prefinishing on external doors as they usually require some minor planing once on site. When you receive the door it should be checked for fit, in most cases external door frames are not completely square and your new door will often require minor planing on site to fit depending on your door frame.
Once this is done then the door must be finished. We cannot overstate how important it is to properly finish timber external doors to provide satisfactory service. All timber will expand and contract as it gains and loses moisture. That's why your door can take on moisture and expand in winter weather. Thoroughly finishing the door will slow this movement to a minimum. It is extremely common to find timber doors that have not been finished properly, almost always in difficult to reach places such as underneath the door.
Even with thorough finishing often timber doors can require minor planing in the first couple of seasons. You should always follow a good maintenance programme with solid oak exterior doors, refinishing them as necessary.
Cardinal exterior doors are heavy and easily damaged in transit. We carefully package them using a sturdy cardboard carton before shipping them with a reputable national courier.