Here at Heritage, we manufacture this door with a full 44mm oak frame with a 36mm inner solid oak panel. The internal boards have a chamfered joint effect to create a look similar to a Mexicano style. The door looks the same on both sides and is an extremely heavy and substantial exterior door. Our state of the art 5 axis machining centre (equipped with the latest tooling) accurately machines each component. This allows us to to produce an exceptional quality door made to BS644 standards.
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 small knot and character in the door which helps to emphasize the door’s solid oak construction. The doors are manufactured to a 44mm thickness for a solid and heavy door with a real feeling of quality. 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. We complete all laminations in house so that we can control the quality.
The centre boards are made from a single 36mm thick oak panel, sealed into the outer frame for excellent weather resistance. The panel is laminated for stability and is routed to created the boarded tongue and groove design that makes for the classic Mexicano look. To meet British Standards on door construction, we use custom designed tooling to create a slightly rounded “V” style joint. This method means we can apply finishes to the correctly specified thickness, which would be impossible with sharp edges.
We use twin 16mm hardwood dowel joints, which are glued and hydraulically clamped to make the mainframe of the door. This is a modern method that results in a strong and accurate construction and means you can be sure your door is made to last.
We handcraft all of our external 44mm doors to each order. The typical lead time is around 3-4 weeks on these oak external doors
The glass opening is a fixed size. We machine this into the central panel of the mexicano style door and finished off with solid oak beading inside and out. The mexicano style glass is approximately 203mm square and the units are 18mm thick.
We use twin 16mm hardwood dowel joints, which we glue and hydraulically clamp to make the mainframe of the door. Our modern method means we can provide a strong and accurate construction.
We handcraft all 44mm external doors to order. The typical lead time is around 3-4 weeks on these oak external doors. For help with measuring up, check out our step by step instructions.
Points to Note
- For seafront properties, or properties highly exposed to wind driven rain, we recommend fitting this door under a porch or covering
- We will only guarantee this door IF you choose to have the door factory finished by us. Selecting unfinished will mean we are unable to assist with doors that are warped, twisted, etc. due to moisture ingress unless a multi stage finishing system has been proven to be used. A care leaflet will be provided with every door detailing the appropriate way for the doors to be finished.
- The doors are made from solid oak however the flat centre panel is cross laminated with an 6mm oak outer layer over a hardwood core. The cross lamination is a time consuming construction method but it helps to ensure the door is more stable and has much more reduced risk of movement than a door made with 100% solid oak. Please contact our sales team for further details.
We manufacture our exterior Mexicano doors using a specially selected grade of prime oak. The oak is bought directly from a number of partner sawmills 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 which visually sets a solid oak door apart from a cheaper veneered door.
All of our Oak is specially kiln dried to 10-12% for use as an exterior door and will exhibit minimum movement in use. As with all timber exterior doors, but particularly with oak, its extremely important to thoroughly finish your new doors to prevent moisture content changes that can lead to door swelling. With all oak doors, it is possible that in the first few years an occasional planing might be required, however the doors tend to settle over time. We strongly recommend you consider our factory finishing system to help reduce this movement to a minimum.
Standard and Custom Sizes
We will make your new external Mexicano door to order to your exact size so even if you have an old property with an unusual door size that's not a problem. 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.
Your new oak door is custom made, and cannot be returned/refunded once manufactured so please check your measurements carefully. On receipt of your measurements your door will be designed in our CNC software. From this a dimension drawing will be sent back for you to confirm so we both have a clear understanding of the size you require.
Please note that your new door is custom made and can take around 2-4 weeks to manufacture depending on how busy the factory is.
Oak is a very popular and attractive timber, but it needs very careful finishing to ensure satisfactory service. We strongly recommend you consider our factory finishing option.
If you choose this option your door will go through a multi stage finishing system. Your door will first be sanded and degreased. After any chosen colour stain is applied, a special sealer is used to protect porous end grain. Following this multiple top coats are applied to a specified thickness. We use a specially designed highly thixotropic finish, applied by a very high pressure spray system, that allows us to build up a highly protective layer on your door. V joint sealer is applied where required between top coats, and the door is infrared cured and sanded between each coat.
This system provides your door with the best protection possible from the weather as well as creating a finish that looks much better than a brush applied finish.
If you choose to have your door unfinished, when you receive the door it should be checked for fit and then prefinished as soon as possible. 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. If you prefer to finish your door onsite, each door is shipped with detailed finishing instructions (see download tab to view a copy) that explain how to create a weathertight finish to your door. You must follow these carefully to ensure satisfactory performance.
Even with thorough and correctly specified finishing, timber doors can occasionally 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.
Oak can discolour over time unless UV protection is given to it within the finishing system. This protection is within the pigment, and therefore it is not possible to give proper UV protection with a clear finish. As standard we recommend a medium oak finish. We can apply a clear finish however you should note that this cannot provide UV protection and your oak door may weather and the timber fade over time if this option is chosen.
We specify and use Teknos water based industrial finishes in our factory finishing facility.
PLEASE NOTE - Prefinished doors are hung in our spray facility to ensure full coverage and a top quality finish. This does mean there will be 2 small screw holes in the side of your door. Please be aware of this before ordering.
We use multiple couriers to ensure your door is delivered safely and efficiently, lead times are as below
Please note, anything to Scotland, Cornwall, or the South Coast can take up to 4 weeks in transit. Please call us for an approximate lead time as time will be dependent on the quantity of doors you purchase
10-15 Working Days
Please add 5 working days for prefinishing/glass
1-7 Doors: 5-10 Working Days (Epic Logistics)
8+ Doors: 3 Working Days (Hallam Express)
We do not currently deliver to Scottish Highlands, Islands, or Ireland
Please give us a call if you are needing your order urgently, express options may be available on a case by case basis