Interior Doors Construction Details

Timbergate

DOOR PANEL CONSTRUCtion

Solid Wood Door Panels:

Timbergate uses solid wood panels on all raised door panels. The door panels are hand-selected for consistency of grain, color, and appearance. Timbergate works to blend these natural wood characteristics for a final pleasing appearance. For, 7/8”, 1 1/8" and 1 3/8" door panels, Timbergate face-to-face laminates two panels together to create the desired panel thickness.

Doors with Applied Moulding:

Timbergate moulded doors are the only doors in the Timbergate lineup to have different size stiles and rails. 5 1/2" wide stiles are used on the two outside stiles, while our standard 4 3/4” wide stiles are used for all center stiles. Standard 4 3/4" wide rails are used for all rails. The additional width added to the two outside stiles, helps to assure the proper clearance needed when using today’s modern door hardware. The uniquely designed moulding used on our Timbergate doors are designed to be used with any of your stile and rail profiles. This ability to choose from any of our standard profiles gives the customer the ability to create very distinctive looks at no up charges. Timbergate moulded doors are available in square panel configurations only. Passage and Double doors have moulding applied to both sides. Bi-Fold units have moulding applied to the front side only. Pocket and Bi-Pass doors are not available.

Veneer Door Panels:

Timbergate veneer door panels are unique. Our veneer panel doors use a high-density particleboard core similar to many other manufacturers. However, most veneer door panels are constructed using a single sheet of wood veneer to cover the core material resulting in a panel that looks very generic. In Timbergate we cover our core material using veneer sheets constructed using many smaller strips of veneer called staves. The use of the smaller staves creates a veneer sheet that looks much closer to a true solid wood panel. The panels are readily available in all standard wood species.

Air Door Construction:

Timbergate uses a proven system of door construction called "Air-Door". Wood cells change in size due to changes in the natural environment based on moisture and humidity levels. This natural shrinking and swelling of wood is natural and to be expected. To compensate and prepare for the "Physics" of wood, Timbergate uses an Air-Door suspension system of construction to allow for the door panels to float in air. Urethane inserts are installed in the door sticking to hold the panels firmly in place while allowing for expansion and contraction. A wood spacer is used on the bottom of the panel instead of the urethane inserts. This eliminates the panel from settling.

Door Sizes:

Standard door height is 6’ 8”. Door heights of 7’ 0” and 8’ 0” are available. All doors come prefitted 3/16” under nominal widths and full height. Custom door sizes are available.

 

RAIL & STILE CONSTRUCTION

Thick Wood Veneers:

Timbergate laminates, thick wood veneer to the Core Stock of the door stiles and rails to form the final door frame components. Timbergate makes this thick veneer by slicing hand select solid lumber to achieve matching wood veneers. This process and the resulting veneer material are far superior in quality, thickness, and wear to typical wood veneer. The thick wood veneer starts as 110 thousands thick before final finish sanding.

Core Stock:

The stiles and rails of Timbergate doors are made of "laminated" pieces of hand selected solid wood. The laminated pieces of wood form the foundation of a solid door, which is designed for stability against warping, twisting, and cupping. These individual pieces of wood are finger jointed, set on edge and face glued for strength and stability.

All inside and outside edges are banded using solid wood. Frames are 4 3/4" wide, top and sides and 8 1/4" wide bottom.

Blind Mortise & Tenon Joints:

Timbergate uses the "time tested" method of mortise and tenon joints for construction of the Timbergate door frame. The Blind Mortise and Tenon joint offers more surface area for the application of construction adhesive to bond the door stiles and rails together. The time-tested method of mortise and tenon construction is worth the extra time during construction.

 

jamb CONSTRUCTION

Solid Wood Jambs:

Timbergate uses select and better solid wood for the interior door jamb. Solid wood jambs are standard with all Timbergate doors. This superior solid wood jamb construction versus particle board is needed to handle the heavier solid wood materials used in Timbergate doors. Solid wood jambs are constructed using wood screws versus the industry standard of pins and staples. The use of wood screws allows for the disassembly of the jamb if desired for field adjustment. Double door units are shipped with the jamb disassembled to allow for ease of handling on the job site. The jamb is easily reassembled on the job site with supplied wood screws. All pre-hung Timbergate doors include a 4 9/16” solid wood jamb and are shipped with a shipping strap on the bottom of the jamb to hold the jamb together during shipment and job-site handling. Other jamb sizes (4 13/16”, 5 1/4”, 6 9/16, and 6 13/16”) are available. Custom jamb sizes other than those listed above are available.

Rabbeted Jambs:

In addition to our solid wood flat jamb we offer both single and double rabbeted jambs. Although rabbeted jambs are typically used in fire rated door applications they can be ordered for use with our standard doors as well. Available in the FC profile only.

Door Stops:

A door stop is included on all pre-hung doors. The stops are solid wood 3/8” thick x 1 3/8” wideand applied at the factory after finishing.

 

Finish

Doors are machine-sanded followed by a thorough hand-sanding to prepare the wood surface for finishing. A penetrating oil stain is then applied and hand wiped. All door panels are pre-stained before door construction and assembly to diminish the appearance of an unfinished line from appearing during the natural expansion and contraction of the solid wood components. The catalyzed conversion sealer coat is sprayed on and oven cured. This special sealer is a blending of alkyd, amino and vinyl resins, which contributes to the overall durability of the finish. This special formula penetrates the grain of the wood and provides a “link” coat between the stain and the top coat. After curing, the sealer is sanded and the door is prepared for a second sealer coat. The second sealer coat is applied and sanded before the final topcoat application. The final topcoat is a catalyzed conversion varnish which is a carefully formulated combination of alkyd and amino resins. After the topcoat is applied, it is oven cured and forms a protective thermoset coating that possesses exceptional stain, moisture and chemical resistance while still retaining its clarity.

Unfinished:
Doors are assembled and machine-sanded to flush the joints and create a smooth, uniform surface. *Timbergate highly recommends additional hand sanding at the jobsite before finishing. Unfinished doors will follow a stain grade wood selection which will have variations in color, grain, and texture. These variations occur. Darker stains tend to reduce the visibility of the variations, light stains and natural finishes tend to enhance the variations.