This door is supplied with a full 44mm frames with 44mm full width internal vertical boards. The internal boards have a chamfered joint to create a look similar to a Mexicano style. Note that this creates a “V” style joint, not the square groove on most Mexicano doors but the look remains similar. The door looks the same on both sides and is an extremely heavy and substantial door. Both door leaves are made using traditional mortice and tenon joints and the two leaves are rebated to fit together.
We manufacture these exterior doors in our Sheffield factory. We use a prime grade of white oak, specially selected to suit external doors. Most of the timber will be clear however you will find the occasional knot in the door which helps to emphasis the doors solid oak construction. The doors are manufactured to a 44mm thickness for a solid external 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.
The centre boards are also a full 44mm thick and feature closed cell foam jointing to guard against water ingress. The boards are tongue and groove jointed at the sides and the bottom to the frames for a very strong and stable door. 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.
All our exrterior mortice & tenon door’s are hand crafted to order. The typical lead time is around 3-4 weeks on these oak external doors Please note that as a custom sized door these cannot be returned. Please check your measurements carefully!
We manufacture exterior stable 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
We will make your new external stable doors 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. Please note that the dimensions are for both leaves, not each leaf
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. Each leaf will come with a seperate oak weather bar which can be fitted on site.
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.
Exterior doors are heavy and Mexicano doors are about the heaviest we make. This can make them liable to transit damage. To avoid this we carefully package them using a sturdy cardboard carton before shipping them with a reputable national courier. Stable doors are packed with each leaf ontop of the other to make a more compact and sturdy parcel.