Specification &

Construction
Of Custom
Stile & Rail
Doors

A Division of Amherst Woodworking & Supply, Inc.

 Custom wood doors can offer a wide variety of functional and æsthetic advantages.
They allow a great deal of latitude in design. There are certain construction basics of which
you should be mindful, so that your goals will be met in a fashion that delivers your design
vision along with functional practicality.

What follows is a discussion of some of the different methods employed in door

construction. Doors must be designed and fabricated to withstand use and abuse as well as
seasonal fluctuations in their environment. No other item of architectural woodwork receives
as much physical wear & tear as a door. Quality construction is of paramount importance.

The effort to achieve original design often leads designers away from traditional
standards. The standards of tradition have generally been derived from practical experience,
so, in your efforts to push the frontiers of design be mindful of the lessons of those that have
gone before.

Location Conditions

The first consideration in specifying a wood door is the environment in which it will be placed.

The principal source of problems with wood doors is

moisture, either an excess, or an extreme lack thereof. Wood
is a hydroscopic material; meaning that it’s moisture content
will change in reaction to its surrounding environment. As it
picks up moisture it will expand, when it gives up moisture it will
shrink. In most cases, it is the “rapid” change of moisture
content that causes problems. A piece of wood, or wood door,
that picks up moisture more on one face than another, will
expand more on that face; i.e. it will warp. Proper finishing, as
will be discussed later, slows down the process of moisture
exchange, and can therefore limit its effects. No finish can
make a door completely impervious to the effects moisture
changes in its environment.

It is the constantly changing nature of wood that

prompted the evolution of the Panel & Frame, or Stile & Rail,
method of construction. Essentially all of the dimensional
changes, due to moisture fluctuations in a piece of wood, occur
across the grain. The changes in length are so small as to be
considered immeasurable. Stile & rail construction utilizes the
lengthwise stability of wood to greatest advantage through
alternation of grain directions, minimizing overall door size
change. (See illustration at left)

Interior Wood Door design criteria is principally driven

by æsthetics, structural considerations, and environment as
related to Relative Humidity. The most common environmental
problem for interior doors is excessive dryness.
Arrows Indicate
Grain Direction

Custom Door Specification & Construction © Amherst Woodworking / Copperbeech Millwork p.1
 Exterior Wood Doors require the same considerations along with weather factors.
Wood doors function best when protected from direct weather exposure. The most common
environmental problem for exterior doors is excessive wetness.

Note: Most manufacturers stipulate a minimum of a 4’ overhang to protect the door

from direct rain and excessive direct sunlight. An exterior door should be expected to easily
withstand occasional precipitation contact, such as from a blowing storm. It is unreasonable to
expect a wood door to endure routine soakings from regular rain or snowfalls. It can be
noticed that buildings having withstood the test of time, have their wood doorways well
recessed from weather exposure.

Exterior doors are, in fact, usually defined as doors subjected to differentials in

temperature of more than 20°, or humidity of more than 10%, between the two faces, at any
time. This means that many applications, such as a bathroom or a garage/house door, would
be considered as exterior even though they have no exposure to weather. The exterior
designation affects choice of materials and warranty term.

Wood Species

The choice of wood for Exterior Doors is more critical than for interior. Exposure to
the elements is very hard on any wood, but there are some with better weathering
characteristics.

Mahogany, Pine, & Spanish Cedar do well for exterior doors, because of good
stability and weathering characteristics.

Cypress is commonly used in the Southeast, where it is native, but does not perform
as well in dryer, northern climates. It has not exhibited good stability and can be subject to
grain lifting, a condition where the growth rings separate.

Douglas Fir has good stability & strength and fair weather resistance, making it
inadvisable to use in a location with direct weather contact.

Western Red Cedar & Redwood have excellent stability and weathering
characteristics, but are very soft, limiting their wear resistance and structural strength.
Redwood’s availability is extremely limited. The western lumbers (Fir, Cedar, Redwood) are
not commonly available in sufficient thickness for solid wood doors, making laminated
construction necessary.

Oak, Cherry, Maple, and most other hardwoods do not withstand direct exposure to
sunlight & rain very well. They can make a satisfactory exterior door with proper construction
methods and protection from the elements, such as a location inside a porch or deep
overhang.

Wood selection for Interior Doors is primarily an æsthetic choice, making the
governing factors cost and availability. As we will see, specie selection can have an impact on
choice of construction methods.

Custom Door Specification & Construction © Amherst Woodworking / Copperbeech Millwork p.2
 Elevation Details

Stile width of interior doors should be a

Top Rail minimum of 4-1/2”. The Architectural Woodwork
Muntin Bar

Institute (AWI) recommends an exterior minimum of 5-

1/2”, although we have found 5” to work well.
Intermediate or Mullion Stiles are generally
~80-100% of the width of the Stiles.
The width of Muntin Bars is usually determined
by the rabbet required for the glazing. Single glazed
Light
muntins can run as narrow as 5/8”, more commonly
being 3/4”. Insulated glazed muntins generally require
a minimum width of 1-1/8”, more commonly being 1-
3/8”-1-1/2” wide. See further discussion under Panels
- “Glazing”
Stile

The Top Rail is usually the same width as the

stiles. This provides an æsthetic as well as structural
balance. Bottom, Lock & Cross Rails are generally
the same width or wider, progressing in width as you
Lock Rail get closer to the floor.
Door components need to be sized to:
Intermediate or
Mullion Stile

1. Provide sufficient structure to the door to

withstand usage and resist sagging.
2. Provide sufficient stability to resist warpage.
Cross Rail 3. Provide adequate area for mounting of
hardware without compromising the above two factors.
Component sizing requirements are heftier for
Panel

commercial & institutional doors because they bear

heavier traffic than residential doors. A 3/4” muntin
bar on a commercial door is not a good idea.
Commercial doors generally require heavier hardware,
Bottom Rail which needs larger stiles & rails than residential doors.
Mortise locks generally require stiles with a minimum
width of 5 to 5-1/2”. Some closers require 7” top rails
for proper mounting. Cross rail placement can be
critical if there is a panic bar exit device used.

Section Details

The Stiles & Rails can either be constructed of solid lumber or laminated for enhanced
stability.

Solid Lumber construction is advisable only for a few

species of lumber, among them; Pine, Mahogany, Spanish Cedar,
and Basswood (interior only). Most hardwoods, Poplar included,
do not have sufficient stability for effective use as solid wood
components in the manufacture of quality doors. Any wood
selected for solid components should be straight grain carefully
dried to 6-8% moisture content (MC).

Custom Door Specification & Construction © Amherst Woodworking / Copperbeech Millwork p.3
 Stave Core construction of stile & rail components provides for superior stability and
straightness. The core is laminated using a stable, low-density lumber such as Basswood or
Pine. The faces are covered with a 1/8” veneer of the appropriate specie, while the edges get
5/8” of the same. Commodity doors use face veneers of 1/32-1/16” thickness. Poplar faces
for paint grade doors work well because the stable core
limits the Poplar’s movement.

Stability in the construction of door components is

not just an issue of warpage. It also affects the tightness
of the joints over time, through seasonal fluctuations.

Stave core construction is also an excellent means to be selective about grain & color
on natural or stain finish doors such as Cherry, Walnut, Maple, or Oak. In addition it can allow
the use of different species on each face of the door, for the purposes of matching different
woodwork in different rooms. The use of different species usually voids warranties against
warpage and should, therefore, be done with care. (See discussion under Maintenance &
Warranty - “Balanced Construction”)

Stave Core construction works equally well for interior and exterior applications.

Joinery

Mortise &
Tenon is the preferred
method of joining stile &
rail components. A
method as old as the
construction of the first
panel door, it is still the
strongest, and most
durable over time.
The tenon,
machined from the end
of the rail, fits into the
mortise, a pocket cut
into the stile. The joint
is machined to a close
tolerance, allowing for
the proper spread and Mortise & Tenon Joint
penetration of adhesive
throughout the joint.

Custom Door Specification & Construction © Amherst Woodworking / Copperbeech Millwork p.4
 Dowel construction is
common among stock, or
“commodity”, doors. Both
the stile and rail are bored to
receive two or three dowels
per joint. The dowels are
typically 1/2” or 5/8”
diameter by 2-1/2” or 3”
long. Some architectural
grade interior doors are
fabricated with doweled
construction. Because of the
advances in adhesives,
doweled joinery can produce
a good quality door. Doweled
doors are less costly and
provide a good alternative
Dowel Joint
where service requirements
do not demand, or budgets
do not allow mortise & tenon
doors.

Adhesives

While there are many types of chemical adhesives used in woodworking, three types
have practical application in door fabrication. There are two particular concerns with adhesives
used in door fabrication. Water resistance and “creep”. Creep happens when the bond
between two pieces of wood holds, but the pieces shrink or swell differentially. This results in
joint separation, such as at the meeting point of a stile and rail.

Polyvinyl Acetate (PVA) adhesives are assembly glues, including such retail brands
as Titebond™ and Elmer’s Carpenter’s Glue™. They have very low water resistance, moderate
creep resistance, and are satisfactory for edge gluing door components such as solid wood
panels for interior doors. Crosslinking PVA adhesives can achieve a Type I waterproof bond,
but still only have moderate creep resistance. These differ from regular PVA’s by the addition
of a catalyst to cure the bond.

Urea Resin Glue, also known as Plastic Resin Glue, is available as a powder mixed
with water, or a liquid resin mixed with a powder or liquid catalyst. These offer very good to
excellent water resistance, and excellent creep resistance. They are easy to mix properly. The
Urea Resin Glue used by Amherst Woodworking misses a Type I rating because of failing the
boiling test. Boiling doors voids the warranty.

Resorcinol Adhesives are also catalyzed. They will give a Type I waterproof bond
with excellent creep resistance. They can be very tricky to mix, being prone to over or under
catalyzing, resulting in weak bond. They are also very temperature sensitive while curing.

Custom Door Specification & Construction © Amherst Woodworking / Copperbeech Millwork p.5
 Stile & Rail Sticking/Molding

Wood doors offer a wide variety of possible molding and panel profiles. Note: Exterior
doors, with direct weather exposure, need the profiles designed to facilitate the shedding of
water. Doors without direct precipitation contact, such as inside a porch, do not share that
concern.

Bead & Cope sticking provides the

greatest structural integrity along with the
lowest cost. The molded pattern is integral to
the stile & rail, providing the most solid panel
retention as well as being an integral
component of the stile & rail joint. Most
manufacturers have a “Standard Sticking” that is used as a default pattern unless a specific
detail is drawn and requested. Custom manufacturers usually offer a variety of sticking
patterns as well as the capability of reproducing existing patterns with a tooling charge.

Applied Moldings can

provide a higher level of detail, but
are more costly in material and labor.
Being applied, and not integral, they
do not provide as high a level of
structural integrity as bead & cope
sticking. Application of the moldings
generally involves face nailing which
requires puttying/filling.
As illustrated, applied
moldings can either be Inset or a
Bolection Molding.

Applied Bolection Molding

Bead & Cope w/Applied

Molding gives some of the best of both
worlds. The higher level of detail from
applied moldings can be achieved while
retaining the structural advantages of
Bead & Cope sticking. Applied moldings
on stiles & rails or panels should be
applied to both faces in exactly the same
pattern to avoid warpage. (See discussion
under Maintenance & Warranty -
“Balanced Construction”)

Custom Door Specification & Construction © Amherst Woodworking / Copperbeech Millwork p.6
 Integral Applied
Moldings can provide a higher
level of detail, while avoiding the
need to face nail in fastening.
This provides a greater degree of
structural integrity in panel
retention, similar to that of a bead
& cope. It also avoids the need to
putty nail heads which is more pleasing æsthetically. This method is, however, the costliest
method of door construction because of the greater precision required in fitting and
fabrication. Selection of molding profiles can also be more limited.

The Sizing of the molded

section, whether bead & cope or
applied, is a function of the joinery.
In mortise & tenon construction, the
thickness of the tenon is the same
as the tongue of the panel, leaving
the balance of the door thickness
available for molding. The thickness
of the tenon should be ~30-40% of the thickness of the door. We most commonly use a 5/8”
tenon for a 1-3/4” door.
This also holds true for glass panel doors with a bead & cope on one face and an
applied stop on the other. (See further discussion under Glazing.)

Panels

Panels are not a structural component of the door. Panels should “float” in the rabbet
or dado that retains them. This allows the panels to change dimensionally independent of the
stile & rail changes. This prevents the introduction of stresses between the panels and stiles &
rails that might cause the door to warp or force joints apart.

Flat Panels can be made with solid

lumber, plywood, or composite materials.

Solid lumber flat panels should be

kept to 14” or less in width across the
grain. This is because of dimensional
variation due to seasonal fluctuations in
humidity.

Plywood or Veneered flat panels provide superior dimensional stability. A wide

variety of veneer species are available for interior use. Exterior use of plywood panels is
generally limited to painted panels utilizing MDO (Medium Density Overlay) plywood, or the
few species that are commonly available in a marine Grade Plywood; Mahogany & Teak. The
commonly available plywoods with decorative veneers are interior grades. Almost anything
can be specially laid up in the way of plywood, but the cost factors will double to quadruple,
and lead-time will be greatly extended.

Custom Door Specification & Construction © Amherst Woodworking / Copperbeech Millwork p.7
 Composite (MDF - Medium Density Fiberboard) panels are appropriate for interior
paint grade construction. Medex® is an exterior grade MDF board that offers the advantage
of a consistent core for shaping an edge, or vee-grooving. It is subject to swelling under
consistent high humidity conditions, and is, therefore, not recommended for direct weather
contact.

Raised Panels can be made with either solid lumber, veneered panels rim-raised with
solid lumber edges, or composite materials.

Solid lumber raised panels, as with flat panels, should be kept to 14” or less in width
across the grain.

Rim-raised panels utilize solid

wood mitred and applied “picture frame”
Veneer Over Edge around a composite panel. The panel is
either pre-veneered, displaying a ~1/8”
border around the veneered section, or
veneered after application of the edge,
eliminating the appearance of a border.
This allows for the stability of veneered
construction with the beauty of shaped
Pre-Veneered Panel solid wood. Rim-raised panels are much
more labor intensive than solid lumber
and, as such, are more costly.

The use of rim-raised panels for exterior doors is limited by the availability of exterior
grades of plywood as discussed under flat panels above. The sandwiched nature of panel
construction can allow for the inclusion of an insulation board in the center of the panel,
greatly improving the R-value of the panel.

Composite (MDF - Medium Density Fiberboard) panels are appropriate for economical,
interior, paint grade construction. The panel raise (edge shape) can be cut directly into the
MDF board. This gives a panel with excellent dimensional stability and the economy of MDF.
The disadvantage is that, without the proper priming of the shaped edge, it will take paint
differently from the flat center surface of the panel.

As with sticking patterns, most manufacturers have a standard Panel Raise Pattern.
Custom manufacturers usually offer a variety of panel raises as well as the capability of
reproducing existing patterns with a tooling charge.

Panel raise profiles can also be enhanced with the addition of an applied molding.

Glazing

Custom doors can accommodate a variety of glazing styles. All glazing for passage
doors is required by code to be safety glazing, either tempered, laminated, wire, or acrylic.
Some states have “Art Glass” exemptions for stained glass or similar products. It would be
advisable to thoroughly investigate any such exemptions prior to specifying anything that does
not qualify as safety glazing.
Tempered lights can be manufactured with or without the small logos in the corner.
Some residential projects prefer lights without logos for æsthetic reasons, especially on ADL
doors where 15-20 logos would be very apparent. This leaves verification of compliance to
purchasing receipts when required. Commercial and Institutional projects are best supplied
with the logos due to yearly inspection of facilities by building authorities.
Custom Door Specification & Construction © Amherst Woodworking / Copperbeech Millwork p.8
 Insulated Glass requires a
sufficient rabbet depth to hide the
spacer used to fabricate the glass
light. Insulated lights are available,
from a few specialty manufacturers,
with spacers or “sightlines” as narrow
as 5/16”. This allows a rabbet depth
of 3/8”. It becomes an issue with
Authentic Divided Light (ADL)
doors requiring insulated glazing. A
muntin bar width as narrow as 1-1/8”
can be achieved with two 3/8” glass
rabbets and 3/8” left in the center for
the tenon. Insulated lights for 1-
3/4” doors are typically 1/2 - 9/16”
overall thickness.
A typical ADL Insulated
muntin bar would be 1-1/2” wide,
with glass rabbets of 1/2” and a 1/2”
wide tenon. The wider muntin bar
affords greater strength, a
consideration for commercial &
institutional doors, and the use of
standard insulated lights.

Single Glazing is usually 1/8 - 1/4” thick. It can be accommodated with a rabbet
depth as shallow as 1/4” allowing for narrow (3/4”) muntin bars on ADL doors. As shown in
the illustration, a single glass panel will not be located at the center of the thickness of the
door. It is bedded in a sealant against the sticking bead at one face of the door, with the stop
taking up the balance of the door thickness. Single glazing
is usually retained by the use of a wood stop, as shown
in the illustration. Putty Glazing is not generally used on
doors because modern putties remain soft & elastic,
providing a superior seal to earlier putty. The softness
does not work well on a door application, being subject to
handling.

Leaded Beveled or Stained Glass, sometimes referred to as Art Glass, requires

special treatment, and is best handled by an art glass specialist.
Leaded glass panels, wider than ~12”, require support bars anchored to the
surrounding frame. The bars help the individual panes resist loosening over time. This is true
with static windows, so it is particularly applicable to a door that is subject to slamming.
Greater energy efficiency can be attained through the use of an exterior clear insulated
light, and then mounting the leaded panel spaced to the inside. Accommodating the insulated
panel, 1/2-3/4” space, leaded panel, and support bars will likely require a door thicker than
the standard 1-3/4”. Use of a single thickness, clear, outer light would save on required door
thickness, but would risk condensation problems between it and the leaded panel.
There are pre-manufactured panels available that incorporate a leaded light sandwiched
inside of a clear, tempered, insulated unit. These can also be custom made. They do not have
any provision for support bars or heat dissipation, an important consideration for stained glass.
The darker panes of the stained glass, absorbing sunlight, can heat up and crack in a sealed
unit.

Custom Door Specification & Construction © Amherst Woodworking / Copperbeech Millwork p.9
 The 1997 code in Massachusetts seems to allow the use of “Assemblies of leaded glass
or faceted glass and items of carved glass used for decorative purposes . . .” (780 CMR
2405.2-9-2) without safety glass panels. Any contemplated use non-safety glass should be
cleared with governing inspectors.

Acrylic Glazing can meet the requirements for safety glazing, but it’s tendency to
scratch easily gives it a poor appearance in a relatively short time period.

Plank and Board & Batten Doors

Plank Doors, typical in some Gothic and Tudor

buildings, do not offer the dimensional stability of Panel & Frame
construction as discussed earlier.
Traditionally constructed Plank Doors are, essentially,
large panels of solid wood. They are generally fabricated with
multiple boards, splined or tongue & grooved (T&G) together.
Having a unidirectional, vertical grain orientation, they are
subject to large width fluctuations, and a tendency to wrack.
This can be a particular problem for exterior doors.
An adaptation of plank construction is Plank on Frame, which
utilizes a mortise & tenon frame (typically 1-1/4” thick), over
which is applied T&G boards (1/2” each face). The frame
provides structure and dimensional stability. The boards are
applied individually, without edge gluing to each other, allowing
them to move independently, minimizing width change and
wracking tendency. The spaces between frame members can be
filled with insulation board, improving R-Value, or deadening
sound for interior applications.
A Plank on Frame door will never equal a Stile & Rail door
for weather-tightness. It is a good compromise where the
original appearance needs to be maintained. Nor are they
generally warranted to the same tolerances.

Board & Batten Doors, typical of the Colonial Period,

have similar problems to Plank doors. The width fluctuations are
largely controlled by the individual application of boards, not
edge glued, to the battens. There is, however, very little
resistance to wracking, given the absence of a frame. The
informal nature of this type of door generally means an
Plank on Frame Elevation imperfect fit to the frame is not a problem for an interior
Typical frame layout application. One should not expect a typical warranty for this
shown with dashed lines type of door either.
Insulation Board for Exterior
Leaded Glass Light

Mortise & Tenon Frame Member Planked "Skin"

Custom Door Specification & Construction © Amherst Woodworking / Copperbeech Millwork p.10
Finishing

One of the most important points in upholding the terms of any door manufacturer’s
warranty is the finishing. An interior or exterior door needs to be promptly and properly
finished on all six sides, protecting it against the elements. Proper finishing slows down the
process of moisture exchange. The slower the exchange, the greater the chance that all the
components of a door will be able to react to the change equally.

Exterior Doors require protection generally to be had through Marine Supply

from the sun and moisture. The trick in houses.
maintenance of the finish on an exterior There are several high quality
door is keeping the sun’s UV rays from Marine varnishes on the market. The
attacking the wood. This is accomplished in Resources page, in the Appendix, has
two ways. contact information.
One is by pigments, which block the A clear-finished wood door with
rays. Paint is the most effective UV heavy sunlight exposure will require
inhibitor, and the best finish for any door. maintenance of the finish every 2-5 years,
A painted finish gives the most complete depending on the quality of the initial finish
protection and requires the least and the degree of exposure.
maintenance. As discussed, paint requires less
Where a stained or natural finish maintenance and provides better protection
is desired, much greater attention needs to than a clear finish. If, for example, a
given to the finishing. The best systems Cherry door is desired to match the interior
are either Marine finishes, or those derived woodwork, consideration should be given to
from Marine systems. Sikkens™ painting the exterior for maximum
manufactures a finishing system involving protection, and clear finishing the interior
1-2 pigmented coats, followed by 2-3 clear where the æsthetics are a premium
coats. The pigmented coats act like a stain, consideration.
æsthetically, while providing a certain
amount of UV blockage. The use of The text of an article, from
pigmented coats also has an advantage “Woodshop News”, on finishing of wood
with woods such as Mahogany & Spanish doors is included in the Appendix. It gives
Cedar, which have a wide range of natural a good overview of the considerations
color variation. Also, direct exposure to involved in this very important final step of
sunlight bleaches color from wood. door manufacture & installation.
Pigments in the finish can help to maintain
the “natural” look of the wood. Painted doors can first be
The second method of protection is effectively preservative treated by brush
through UV absorbers in the clear coats. or dipping, after fabrication. Industry
Depending on the manufacturer, anywhere Standards for preservative treatment of
from 3 to 7 coats may be recommended. finish millwork are specified by the National
The highest quality Marine (Spar) and Wood Window and Door Manufacturers
Millwork exterior varnishes have higher Association (NWWDA) in their bulletin
proportions of these absorbers. “NWWDA I.S.4-94 Water Repellant
Manufacturers technical data sheets will list Preservative Non-Pressure Treatment for
the proportion of solids, which is a very Millwork”. Information for contacting the
good starting point for determination of NWWDA is given under “Resources”. It is
product quality. There is, however, no also covered briefly under 100-S-10 of the
commonly listed percentage of UV Architectural Woodwork Quality Standards
absorbers. The best exterior varnishes are Illustrated.

Custom Door Specification & Construction © Amherst Woodworking / Copperbeech Millwork p.11
Quality Standards

The Architectural Woodwork Institute (AWI) establishes the quality standards that are
applicable to architectural millwork, custom stile & rail doors included. AWI details the
requirements of it's three grades, Economy, Custom, & Premium in the Architectural
Woodwork Quality Standards Illustrated (QSI). These grades cover quality of machining
and joinery, as well as permissible characteristics of materials including color & grain matching,
sapwood & heartwood, etc. (For information on AWI Publications see Resources page.)

One should expect a higher level of “fit & finish” on a custom door than a commodity door.
Finish sanding will still be required prior to application of the finish. The degree of sanding
required will depend on the grade of door specified. A copy of the page covering section 1400-S-
10 “Smoothness of Exposed Surfaces”, in the AWI QSI is included in the Appendix.

While AWI covers the standards for the manufacture of custom doors, the National Wood
Window & Door Association (NWWDA) (see “Resources”) addresses issues of storage &
handling, finishing, installation, and maintenance. A copy of NWWDA’s “How to Store, Handle,
Finish, Install, and Maintain Wood Doors” is included in the Appendix. NWWDA’s members
primarily engage in the manufacture of “commodity” type doors.

Maintenance & Warranty

A copy of Amherst Woodworking’s door warranty is included in the Appendix.

Probably 95% of all door failures are caused by improper care of the door or installation in
an improper environment. Properly constructed, installed and finished wood doors can be
expected to give a long service life.

Relative Humidity (RH)

Wood doors should not be subjected to sustained RH levels below 25% or above 55%.

Northern climates are very dry in the winter heating season. Indoor environments,
without humidification, can easily drop below the 25% RH level. At this level there is risk of
warpage and joints pulling apart, even when properly finished.

Conversely, excessive RH can cause warpage and joints to be pushed apart.

By slowing the exchange of moisture, proper finishing allows a door to withstand the
effects of temporary humidity extremes, as experienced in the months of February and August.

Balanced Construction

Doors, and any other wood panel for that matter, need to be constructed and finished in
balance. The same type and number of coats, of finish should be applied to both faces.
Decorative moldings applied to one face should be applied to the other, in the same pattern.
Doors with different wood specie on each face cannot be warranted against warpage because
woods react differently to changes in humidity. Practically, doors with different faces will usually
work fine, as long as the two species are similar in their density and stability characteristics.
Likewise, many exterior doors have a painted exterior face and a transparent finished interior.
These function well if the thickness of the finish film is the same on both faces.

Custom Door Specification & Construction © Amherst Woodworking / Copperbeech Millwork p.12
 Appendices

Historical Design Illustrations 7 pages

Exterior Finish Article 2 pages
AWI Section 1400 sample page 1 page
Sample Door Warranty 1 page
NWWDA Bulletin 2 pages
How to store, handle, finish, install and maintain Wood Doors
Resources & Bibliography 2 pages
 Historical Design Appendix
The following pages have reproductions of drawings from the
National Park Service’s Historical American Buildings Survey (HABS).
Represented are sections & elevations of doors from various periods
of American architecture, along with section details from Copperbeech
Millwork’s (CBM) inventory of sticking, applied molding, and raised
panel patterns.

1700-1765 Early Georgian

One HABS drawing, two CBM patterns

1765-1835 Late Georgian & Federal

Three HABS drawings, five CBM patterns

1830-1860 Greek Revival

One HABS drawing, five CBM patterns

1840-1910 Victorian - Gothic, Italianate, 2nd Empire, Stick, Queen Anne

Period catalogue elevations & sections.

1905-1930 Craftsman
One HABS drawing, three CBM patterns

www.cr.nps.gov/habshaer/
The Historic American Buildings Survey (HABS) and the Historic American Engineering Record
(HAER) document achievements in architecture, engineering, and design in the United
States. As of March 1998, the collection contained more than 363,000 measured drawings,
large-format photographs, and written histories for more than 35,000 historic structures and
sites dating from the seventeenth to the twentieth century.
File #MA-104, Historic American Buildings Survey, www.cr.nps.gov/habshaer/, Early Georgian

1700-1765 Early Georgian

Configuration: 4, 6, & 8, usually rectangular, panels
Sticking: Ovolo (w/o quirk), also called “thumb bead”
Panels: Feather edge raised
Materials: Pine, usually painted
Notation: Entrances featured elaborately molded surrounds.

Selections below are appropriate to period from Copperbeech Millwork patterns.

CB 7859
CB 7900 Raised Panel
Sticking

CB 7857
CB 7900 Raised Panel
Sticking
 File #NJ-311, Historic American Buildings Survey, www.cr.nps.gov/habshaer/ Built 1810

1765-1835 Late Georgian & Federal

Configuration: 4, 6, & 8, usually rectangular, panels
Sticking: Ovolo, ogee, or applied moldings. Sometimes carved.
Panels: Flat, sometimes adorned with an astragal mold. Raised panels/late Georgian.
Materials: Pine, painted, some interior use of natural Mahogany.
Notation: Entrances featured sidelights & fan light transoms, sometimes elaborately
grilled. Decorated w/carvings & tracery applications.

CB 3071
Sticking & molding patterns shown might
CB 7912
Sticking be considered as reasonably replicating
period details.

CB 3569
CB 7902 CB 7875
Sticking CB 7869
Panel Raise Panel Raise

CB 3616
CB 7909
Sticking
File #NJ-152, Historic American Buildings Survey, www.cr.nps.gov/habshaer/ Built 1795

File #NJ-525, Historic American Buildings Survey, www.cr.nps.gov/habshaer/ Built 1795

File #NJ-449, Historic American Buildings Survey, www.cr.nps.gov/habshaer/ Built 1850

1830-1860 Greek Revival

Configuration: 4, 5, & 6 rectangular panels
Sticking: Square edge, slightly beveled, or Grecian (elliptical) ovolo or ogee
applied moldings.
Panels: Flat, or raised w/square rebated edge.
Materials: Pine, painted. Some interior use of Mahogany.
Notation: Entrances featured rectangular sidelights & transoms

CB 7919 Possible Copperbeech patterns for

Greek doors. CB 7856 panel raise not
Sticking

truly authentic due to bevel.

CB 3414 CB 3615

Custom Panel Raise

CB 3432 CB 3426

CB 7856
Custom Panel Raise Panel Raise

CB 3615
Selections from the Combined Book of Sash, Doors, Blinds & Mouldings, Rand McNally & Co., 1898

1840-1910 Victorian - Gothic, Italianate, 2nd Empire, Stick, Queen Anne

Configuration: Multiple panels & lights. Usually selected from catalogues.
Sticking: Standard catalogue sticking patterns for simple interior doors to deep profile
bolection moldings for entries & primary rooms.
Panels: Flat, raised, carved, & applied ornamentation.
Materials: Painted Pine, Fir, Yellow Pine, Birch, Oak, Mahogany, Walnut
Notation: Wider use of glazing as it became less expensive. Clear, colored, etched, leaded.
 File #CA-1985, Historic American Buildings Survey, www.cr.nps.gov/habshaer/
Built 1906 – Greene & Greene Architects

1905-1930 Craftsman
Configuration: Tall narrow panels or lights.
Sticking: Square edge.
Panels: Flat.
Materials: Fir & Oak. Classically natural finished.
Notation: Styling is achieved through stile & rail configuration. Sometimes ornamented
with applied “brackets”.

CB 7916 & CB 7924 sticking patterns below should be considered

“in the style of”, not necessarily historically accurate.

Square
Sticking

CB 7916 CB 7924
Sticking Sticking
 The following text was written by Bob Flexner, and appeared as an article in “Woodshop News” in the
March 1996 Issue. Bob operates a shop in Norman, Oklahoma, and is the author of Understanding Wood Finishing.

Protecting Exterior Doors

Sunlight and Rain are Formidable Opponents
Wooden exterior doors made of high The next best locking agent is a
quality woods and finished with a clear chemical that absorbs UV light. These
finish are very popular. There's no question chemicals are much like the sunscreen
that many of these doors are stunningly agents used by beach-goers. They convert
beautiful. The problem is finding a reliable ultraviolet light energy to heat energy that
way to finish them so they hold up to sun dissipates. UV absorbers don't hide wood,
and rain without a great deal of maintenance and they are fairly effective at preventing
- which most people are unwilling to wood deterioration under a finish.
perform. The problem with UV absorbers is
that they are very expensive, and a
Effects of the sun significant amount has to be included in the
finish to be effective. It isn't enough to add
Light is the principal enemy of a few drops to a vat and claim that the
paints and finishes. Over a period of time, product contains UV absorbers. The
ultraviolet (UV) rays from light, especially products need to contain at least 1 to 3
from sunlight, break down paints. You can percent by weight, and this increases the
see this on cars and buildings that have been cost of the finish considerably.
exposed to the sun for many years. The The most common finishes that
paint has dulled and begun to chalk. If you contain sufficient UV absorbers are marine
catch the paint before the damage has gone varnishes. These varnishes cost from $50 to
all the way through, you can often rub off $100 a gallon. Unless you buy them mail
the dullness with abrasives and expose paint order, they are difficult to find, except in
that looks shiny and new. coastal areas.
UV rays also break down clear
finishes. But most peel before dulling and Effects of moisture
chalking become problems. They peel
because the UV rays penetrate the film and Moisture also causes finishes to peel.
cause the wood underneath to deteriorate. But, in order to do so, it has to get between
The lignin that glues the cells of cellulose the finish and the wood. There are two
together loses its strength, and the surface ways moisture can do this:
cells separate from the rest of the wood. • by penetrating the finish film;
When this happens, the finish, which is • by penetrating a crack in the film
bonded to these surface cells, peels. and working through the cells behind the
The best sun-blocking agent, and finish.
thus the best UV protector for finishes There are several finishes, for
applied outdoors, is pigment. Pigment example, oil, shellac, and to some degree,
blocks UV rays, so the wood underneath lacquer, that do not resist moisture
doesn't deteriorate. But it also hides the penetration well. If it should rain on a door
wood, which defeats the purpose of using finished with one of these finishes, it won't
beautiful woods in the first place.
be long before the finish begins to peel (or sheen on such a soft finish. Flatting agents
simply disappear, in the case of oil). reduce the durability of the finish.
Two-part finishes, like catalyzed • Many coats of marine varnish are
lacquer, conversion varnish, epoxy, and required to achieve sufficient UV blockage.
polyester, resist moisture penetration well, Boat owners commonly apply eight or nine
but they cure too hard to keep up with wood coats. Few homeowners are willing to do
movement outdoors. Rain doesn't cause the this, or pay for someone else to do it.
initial problem. It is cracking due to the • As the film dulls, the deteriorated
hardness of the finish. Then rain can get surface layer should be sanded off and
through and cause the finish to peel replaced with fresh coats. (UV absorbers
Other finishes, especially varnishes, block penetration through a film, but they
also resist moisture penetration well, and don't keep the film itself from deteriorating.)
they can be made very flexible so they keep This should be done every year or two
up with wood movement outdoors. When depending on how much the door is exposed
made flexible, these varnishes are often to the sun. This amount of maintenance is
called spar or marine varnish more than most people want to do.
The best of these varnishes are made
with phenolic resin and tung oil. They don't The best solution
crack as quickly as those made with
polyurethane resin, but they do dull a little There is only one really sure solution
quicker for keeping a clear finished exterior door in
good shape for many years. This is to
Limitations protect the door from exposure to sun and
rain. On the north side of buildings where
Even the best marine varnishes have the sun is not a problem, all that might be
limitations on exterior doors. Most of these needed is a storm door. Where the sun does
doors are frame-and-panel construction, and contact the door, the solution is to build an
no finish is flexible enough to keep up with overhang. The overhang has to be large
the expansion and shrinkage of the panels. enough to shield the door completely from
As soon as a crack opens up where the contact with sun and rain.
panels slide into the frame, water can get in, Even with a storm door or overhang
work its way under the finish, and cause it to the door should be finished with a flexible
peel spar varnish, however, because the door will
Every time this happens, the loose shrink and expand a lot due to humidity
finish will have to be scraped or sanded off changes. But UV absorbers won't be needed
and fresh coats applied. If the water has in the finish.
stained the wood, the stain can be bleached
out with oxalic acid
Marine varnishes have several
downsides as well
• They are very glossy finishes,
glossier than most people want on their
exterior doors. They can be dulled by
rubbing with an abrasive like steel wool, or
by adding a flatting agent. But rubbing is
extra work and it is difficult to get an even
 Amherst Woodworking & Supply, Inc. PO Box 718 30 Industrial Dr. Northampton, MA 01061

Door Warranty
Doors manufactured by Amherst Woodworking & Supply, Inc. (AWW), or its subsidiary Copper Beech Millwork, are warranted to be
free of defects in material and workmanship which would render them unserviceable or unfit for ordinary recommended use.

Interior doors are warranted for a period of two years from the date of delivery.

Exterior doors are warranted for a period of one year from date of delivery. Exterior doors are doors subjected to differentials in
temperature of more that 20º, or humidity of more than 10%, between the two faces, at any time.

All doors must be inspected immediately upon receipt, and should a door be suspected of being defective, AWW must be notified in
writing within 30 days of shipment by the original purchaser. No machining, fitting or alteration of any kind should take place until AWW can
inspect the door. Any alteration that takes place before the inspection may void the warranty. Should a door be determined by AWW to be
defective, we will at our option, either:
A) Repair the door without charge.
B) Replace the door (in the same state of fitting/ finishing in which the door was originally supplied), without charge.
C) Refund the original price of the door.

If AWW elects either option B or C: The door will be shipped to us at our expense and under our instructions, and the refund/
replacement will be made upon receipt of the door by AWW.

Any incidental costs incurred, such as removal of the original door, fitting and rehanging of the replacement door, or re-machining or
re-finishing of the replacement door (in doors not originally supplied in that state), are not the responsibility of Amherst Wood Working and are
not covered by this warranty.

Doors must be handled, stored, installed, finished, and maintained in accordance with “How to Store, Handle, Finish, Install and
Maintain Wood Doors” as published by the National Wood Window and Door Association (NWWDA).

Wood is a hydroscopic material, and under normal conditions, some movement will occur. Due to the natural movement in wood, any
slight surface checking or minor cupping shall not be considered a defect. This movement in properly constructed raised panel doors may show
up in expansion or contraction of the panels with normal environmental changes. This is not considered to be a defect.

Warped doors will not be considered defective unless the deflection exceeds 1/4” in any 3’0”x7’0” section. Warp is any distortion in
the door itself as opposed to it’s relationship to the jamb, or the adjoining door in double units. The amount of warp shall be determined by
placing a straight edge corner to corner across the concave face of the door and a measurement taken at the maximum point.

If a door is determined to be defective due to warping, Amherst Wood Working may elect to allow the door to remain on site for a
period of up to 12 months after installation, in order to allow the door to fully acclimate to the location’s environmental conditions.

Proper sealing of doors that have been sold as unfinished is the responsibility of the purchaser. Failure to properly seal the door will
void the warranty. All doors must be sealed on all surfaces including edges, and glass and hardware cut-outs. An exterior finish must be used on
any exterior door, and any improperly maintained door will not be covered.

Exclusions
This warranty does not cover:
1. Any improperly installed door.
2. Doors that are improperly handled at the site including: not being stored flat, or being exposed to extreme changes in the environment
without protection.
3. Natural variations in wood color, texture, character, or cut.
4. The appearance of field finished doors.
5. Normal wear & tear including wear through of finish.
6. Incompatibility of hardware with a particular door construction.
7. Doors with stiles less than 4” wide.
8. Doors not of traditional stile & rail construction such as “Plank on frame” style doors.
9. Failure to supply adequate overhead protection four feet from the face & edge of the door.

This warranty is applicable only to doors manufactured by Amherst Woodworking & Supply, Inc. AWW also sells doors purchased
from other manufacturers. Those doors are covered by the individual manufacturers warranties, copies of which are available from AWW on
request.

As warranty terms are subject to change, project information requested below is required for warranty to be valid.

Project Sold to

Location Delivery Date

AWW Representative

DOORWAR1.DOC 11/30/2003 p.1

 RESOURCES

The Architectural Woodwork Institute (AWI) Woods of the World - CD-ROM

1952 Isaac Newton Square W Tree Talk, Inc.
Reston, VA Burlington, VT
703-733-0600 FAX 703-733-0584 800-858-6230 FAX 802-863-4344
wow@together.net
www.awinet.org
www.woodwed.com/~treetalk/home.html
Publishers of the Architectural Woodwork Quality
This is a CD-ROM detailing “information on up to 910
Standards Illustrated, the recognized authority for
wood species and products, covering 95% of all the
specification standards of Architectural Woodwork,
wood in trade. Common names, uses, distribution,
Finish Carpentry, and Wood Doors.
environmental profile, physical & working properties,
and mechanical values. Covering all the important
Amherst Woodworking & Supply, Inc. species in North America, Europe, Africa, Latin
Copper Beech Millwork (div.) America, and Asia. Full-color pictures. As many as
PO Box 718 30 Industrial Dr. 3,500 species' distribution maps. Products sectors of
Northampton, MA 01061 the more than 135 countries featured on the maps.
413-584-3003 FAX 413-585-0288 Searching capability.”
800-532-9110 www.copperbeech.com
E-mail: amwooco@copperbeech.com www.cr.nps.gov/habshaer/
The Historic American Buildings Survey (HABS) and
Manufacturers of Architectural Millwork including the Historic American Engineering Record (HAER)
cabinets, doors, windows, moldings, and document historical architecture in the United States.
monumental fabrications. The Copper Beech The collection contains more than 363,000 measured
Millwork Book of Moldings, contains 44 pages of full drawings, large-format photographs, and written
scale molding profiles. It is supplied free on request. histories for more than 35,000 historic structures
dating from the 17th to the 20th century. Am effective
National Wood Window & Door Assoc. (NWWDA) way to search for period examples is to use a date as
Des Plaines, IL a keyword.
847-299-5200 FAX 847-299-1286
www.nwwda.org Marine & Exterior Finish Manufacturers
Sets standards relative to the manufacture of “stock”
type doors & windows. Custom and hardwood doors Epifanes North America Inc.
are better specified under the stricter quality Thomaston, ME
standards of the Architectural Woodwork Institute. 800-269-0961 FAX 207-354-0387
www.epifanes.com
Forest Products Laboratory (FPL) Manufacturers of Epifanes Yacht Coatings.
Madison, WI
608-231-9200 FAX 608-231-9592 Kop-Coat Marine Group
www.fpl.fs.fed.us Rockaway, NJ
Research laboratory for the US Forest Service. An 800-221-4466 FAX 973-625-8303
excellent resource for technical data on North www.kop-coat.com
American lumber species. Manufacturers of Woosey Z-Spar and Petit Marine
Varnishes.
Forest Products Research Society (FPRS)
Madison, WI Sikkens Decorative Wood Finishes
608-231-1361 FAX 608-231-2152 Troy, MI
www.forestprod.org 800-833-7288
Forest Industry trade research group. sikkensnam@aol.com
Manufacturers of Sikkens Cetol finishing systems for
Marine and Millwork applications.

Wood Selection Criteria for Interior & Exterior Architectural Millwork & Finish Carpentry - Amherst Woodworking - Nov-03
 A Select Bibliography The Architectural Heritage of the Piscataqua, JM
Howells
Classical Architecture, Robert Adam Architectural Book Publishing Co., 1938, 1965
Viking Penguin, London, 1990 edition
An excellent guide to The Orders and theories of An excellent survey of the Portsmouth NH area,
classical architecture, well illustrated. with interior & exterior photos, drawings and
sections of Georgian & Federal architecture.
The American Vignola, William Ware
Dover reprint of the 1903 edition, 1994 The American Builder’s Companion, Asher
A guide to classical architecture used by many Benjamin
neo-classical, early 20th century Architects. Da Capo Press 1972 reprint of 1806 work on
Federal (Adam) style. Detailed elevations &
A Building History of Northern New England, sections.
James Garvin
University Press of New England, 2001 The Architect or Practical House Carpenter,
A close look at the details of early Colonial, Asher Benjamin
Georgian, Federal, and Greek Revival building Dover 1988 reprint of 1830 work on Greek
styles. Revival style. Detailed elevations & sections.

A Field Guide to American Houses, Virginia & Practice of Architecture, Asher Benjamin
Lee McAlester Da Capo Press 1972 reprint of 1833 work on
Alfred A. Knopf, 2000 Greek Revival style. Detailed elevations &
A style manual for American architecture, mostly sections.
referencing exterior details.
Woodward’s National Architect, Woodward &
The Elements of Style, Stephen Calloway editor Thompson
Simon & Schuster, 1996 Da Capo Press 1975 reprint of 1869 pattern
A general overview of architectural details in book of Gothic, French, & Italianate styles.
British & American styles from the 15th through Detailed elevations & sections.
the 20th centuries.
Victorian Architectural Details, Cummings &
Handbook of Building Crafts in Conservation, Miller
Jack Bowyer The American Life Foundation, 1980
Van Nostrand Reinhold, 1981 Reprint of two pattern books (1868 & 1873) for
Reprint and commentary on Peter Nicholson’s Mansard, Italianate, & Bracketed style houses.
The New Practical Builder and Workmen’s
Companion from 1823. A British pattern book. Palliser’s Late Victorian Architecture, Palliser &
Palliser
The Theory of Mouldings, C. Howard Walker The American Life Foundation, 1978
JH Jansen, Cleveland, OH, 1926 Reprint of two pattern books (1878 & 1887) for
A detailed examination of origins, profiles, late Victorian style houses.
combinations, materials, architectural styles.
Cabinetmaking and Millwork, John Feirer
Colonial Interiors, Colonial and Early Federal, 1st Charles Bennett Publisher, 1967 original
series 1923 A practical manual for machine use, compound
Colonail Interiors, 2nd series 1930 miter settings, etc.
Colonial Interiors, Federal and Greek Revival,
3rd series 1938 www.abebooks.com
Bonanza Books, William Helburn, NYC www.alibris.com
Interior photos, some line drawn elevations &
sections www.abaa.com
All resources for out-of-print books.

Wood Selection Criteria for Interior & Exterior Architectural Millwork & Finish Carpentry - Amherst Woodworking - Nov-03
 Presenters
David Short is President of Amherst Woodworking & Supply, Inc. in
Northampton, MA. He received a BA in Fine Arts from Hampshire College in 1975
having studied Sculpture and Furniture Design. In the Fall of that year he started
making furniture and small woodworking projects, under the name of The Amherst
Wood Company, located in a 600 sf. Workshop in North Amherst, MA. David was
President of the New England Chapter of the Architectural Woodwork Institute (AWI)
in 1992-93, and current serves on the Board of Directors as a Past President.

Karen LaVerdiere is Vice President of Amherst Woodworking & Supply, Inc.

Ms. LaVerdiere received a BS from The University of Massachusetts, and a Masters
from Springfield College. She started her own construction business in 1985, building
residences and light commercial projects. Karen joined Amherst Woodworking in 1993
as a sales associate, becoming Sales Manager in 1994, and Vice President in 2001. She
is a member of the Board of Directors of the Home Builder’s Association of Western
MA.

Amherst Woodworking & Supply, Inc. is comprised of two operating divisions.

The Copper Beech Millwork division specializes in supply of competitively priced,
high quality, architectural woodwork components for clients managing their own
millwork needs. Projects requiring complete management services such as shop
drawings, field dimensioning, and coordination with other trades are run by the
Amherst Woodworking division.
The Company occupies a 33,000 sf. facility, manufacturing moldings, doors,
cabinets, windows, columns, and ornamental fabrications. They work on projects for
Academic, Corporate, Medical, and Residential clients throughout the Northeast.
Restoration & Reproduction work is a specialty.
The Copper Beech Millwork division publishes a 45 page Book of Moldings
featuring approximately 350 of their over 3000 molding patterns. An electronic file is
available with approximately 1400 patterns. It is based in AutoCad. Also available is a
24 page Contractor’s Price Book with inventory listings, product information and
prices for stock moldings, hardwood & softwood lumber items, mantels, decking, and
more.
Manufacturers of Fine
Wood Doors, Moldings,
and Architectural
Woodwork
800-532-9110

A Division of:

Amherst Woodworking & Supply, Inc.

PO Box 718 30 Industrial Dr. Northampton, MA 01061
413-584-3003 www.copperbeech.com Fax 413-582-0164