At E. F. San Juan, we often hear the question, “Why are solid wood doors made of multiple pieces rather than a single slab?” Many people envision solid wood as one unbroken piece. While this is possible, using a single chunk of wood presents risks. For example, a crack in that piece can compromise the entire door.
To ensure stability and longevity, we employ a technique known as a stave core, where smaller pieces of wood are carefully glued together. This method allows the natural movements of the wood to work together, creating a straight, resilient core that is less prone to warping or cracking over time. We then apply beautiful veneers, offering flexibility in design—whether it’s a stunning cathedral grain or a sleek finish, we can achieve a client’s desired aesthetic without sacrificing stability.
CHALLENGES
Creating high-quality solid wood doors, such as our signature Invincia® line, involves several challenges. Our craftsmen, with their eye for detail and precise measurements and cuts, ensure that each door meets our high standards. Additionally, the veneer application process demands careful attention, as even pressure is essential for a flawless finish.
SOLUTION
Our solution lies in a design approach tailored to meet client needs while ensuring durability. By employing engineered cores and high-quality veneers, we create doors that fulfill aesthetic desires and stand the test of time. The process involves planing the wood surfaces, selecting the finest veneers from our stock, and utilizing a pneumatic clamping system for even pressure during application.
Once the components are prepped, they are precision-sized using our TigerStop saw, and each piece is carefully labeled for the CNC operator to transform into a finished door. This engineered approach effectively addresses moisture and wood movement, resulting in a product that looks exceptional and performs reliably, providing lasting satisfaction for our clients and enhancing the value of their homes.
