Here at Heritage, we supply the Stafford Oak External Door with a full 44mm frame and a cross laminated 37mm inner panel. We then machine the panel with v grooves to create the look of a boarded door. However, this is without the weather permeability issues that a board door can create. Our machine gently sweeps the top rail to add interest and style to the door. The door is identical on both sides and is an extremely heavy and substantial interior door. We will make each door to your exact size, and you can specify any size up to 2100 x 950. For help measuring, check out our step by step guide!
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 in the door which helps to emphasize the door’s solid oak construction. Our expert staff manufacture the doors to a 44mm thickness for a solid external heavy door. We make the stiles and rails 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 perform all laminations in house so that we can control the quality.
The centre panel using a cross laminated hardwood core with oak panels to the outer faces. This creates an incredibly strong and stable door. We manufacture the Stafford door frame using twin 16mm dowel scribed joints for a strong foundation. Then, we glue and hydraulically press each door frame to make a solid mainframe to the door.
If you choose a stable door, we will supply the door with a rebate central split rail with twin weather seals built in. We can also make the door with a glazing unit to allow light in. We can supply the door unglazed for you to source and fit your own glass, or we can preglaze your door in a wide range of glass options. For further information on glazing please check under the finishing tab.
We make our stunning Stafford doors on the latest 5 axis CNC machinery, and design them to meet the standards set out in BS633. Our professionals make every external 44mm door to order and 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
- We recommend that these doors are fitted under a porch or covering if they will be constantly exposed to weathering. (i.e. sea front properties).
- You must carefully finish oak for use outdoors. We will only guarantee this door IF you choose to have the door factory finished by us. This finish uses a multistage process, including end grain and panel joint sealing along with multiple top coats. If you select unfinished, this will mean we are unable to assist with doors that warp or twist due to moisture ingress unless a 3 stage end grain sealer system has been proven to be used. A care leaflet will be provided with every door detailing the best way for the doors to be finished.
- We make the doors from solid oak, however we use flat panels that we cross laminate with an oak overlay panel to each side. The cross lamination is to ensure the door is more stable and has much more reduced risks of movement than a door made with 100% solid oak. Please contact our sales team for further details.
Need a frame? Consider our door set option!
We manufacture exterior Stafford 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 emphasizing 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 Stafford door 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.
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. 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
3-5 Working Days
We do not currently deliver to Scottish Highlands, Islands, or Ireland