How Custom Doors are Made: 10 Steps to a Beautiful, Durable Unique Door


When we think about making our homes look better, the front door is a key place to start, since it makes the first impression.

We’ve put together 10 important steps that make sure your custom exterior doors (or custom interior doors are both attractive and long-lasting.

We begin by picking the right materials—each one has its advantages and disadvantages that need careful consideration.

But how do we ensure that these choices not only look great but also last a long time?

Stick with us as we uncover the methods and tips for creating the perfect mix of appearance and durability in your next custom door project.

Gathering Information

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The first step in creating your custom exterior door is to understand what you like and how much you want to spend. Let’s talk about what kind of perfect door you imagine—maybe you prefer a sleek, modern look, or you might like something warm and rustic. You’ll choose from different types of doors.

Do you like the traditional style of a Dutch door, or do you prefer the smooth operation of sliding panels? For those seeking a rustic or traditional look, barn doors are another option that combines style with functionality. We’ll make sure you don’t feel overwhelmed. We’re here to help you at every step to ensure the door fits your needs and makes you happy every time you return home.

Selecting Wood for Your Door Style

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After you pick the style of your door, you’ll navigate the crucial wood selection process to ensure the best type of wood complements your aesthetic and enhances the door’s longevity, especially if your door is directly exposed to the elements. Whether you aim for a timeless or modern look, the choice of wood significantly impacts the final appearance and durability of your exterior wood door.

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In discussing wood selection, we often recommend robust woods like Sapele mahogany for its deep color and lasting durability. Douglas fir is also a top choice for its strength and appealing grain patterns, making it versatile for both classic and contemporary designs. Each wood species offers unique benefits and appearances, guiding you to make an informed decision that ensures your door is not only visually stunning but also enduring.

Let’s ensure your door is better than you imagined!

Choosing Hardware

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You’ll want to choose door hardware at hardware store that fits your style and makes your door look great. It’s important to pick the right hardware because it needs to work well and look good with your door. Here’s what we think about:

  • Material and Finish: We’ll pick something that goes well with your door’s wood and style, like brass, bronze, or matte black.
  • Durability and Security: We’ll make sure the hardware can handle the weather and wear, and keeps your home safe.
  • Design Details: Whether you like old-fashioned handles or simple locks, we’ll find the best fit for you.

We’ll work together to make sure the hardware isn’t just an extra, but a key part that makes your door stand out.

Picking Glass for Exterior Doors

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After picking the best hardware, let’s look at the glass options to make your door look better and work better too. We’ve many types of glass that can make your door more attractive and useful. Whether you want more sunlight with sidelights or a glass pane, or you prefer a textured glass for more privacy, we’re here to help.

We get our high-quality glass from Bucks County, PA, to make sure it not only meets but goes beyond your expectations. It’s important to find the right mix of good looks and usefulness. Let’s pick a glass that shows off your style and meets your needs, making your custom door really special and welcoming.

Designing the Custom Door

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Let’s explore the exciting world of materials and designs to make sure every part of your custom door matches your vision and style. The door design is crucial in achieving the desired aesthetic and functionality, emphasizing the importance of tailored designs, large windowscapes, and glass selection based on the specific door design and budget.

We can choose from woods like warm mahogany or rustic oak to start shaping your door. Door style is a key consideration in the design process, with a variety of styles available to meet customer preferences, highlighting the intricate details and personalized service involved in selecting the door style for your project.

You can pick from different handles and locks, from old-fashioned ones to modern styles, that not only make your door safe but also add beauty.

You can also choose different types of glass, like frosted for more privacy or colored stained glass for a splash of color.

We’re here to help you with every decision, making sure it’s a fun and rewarding experience. Let’s work together to create something beautiful!

Engineering the Structure

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When making your custom door, we carefully dry the wood until it has less than 12% moisture. This makes the door stable and long-lasting. We know that a door is more than just how it looks; it’s about creating an entrance that lasts.

To do this, we use top-quality wood and arrange it in a way that makes the door very strong. This helps prevent the door from bending out of shape over time, making it not only nice to look at but also very tough.

We also want to make things clear—doors made this way are usually more dependable than those made from only solid wood because of our detailed process. We’re committed to making doors that endure through time and weather, keeping you happy for many years.

Precision Cutting

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How do we make sure every custom door is perfect? We focus on precise cutting, including the critical step of cutting holes for doorknobs and hinges with utmost precision. This process requires careful attention to detail to ensure the door’s functionality and aesthetic appeal. We use the best technology and skilled workers to ensure every cut is exact, including the specialized task of cutting holes. Here’s what we do:

  • Advanced CNC Machines: These machines cut each wood piece very accurately, including the precise cut holes needed for hardware installation.
  • Skilled Workers: Our team is very good at making even the most detailed designs and adept at using specific tools and techniques to cut holes accurately.
  • Regular Quality Checks: We check each cut piece carefully, including the accurately cut holes, to make sure it matches the design.

We work hard to ensure our doors aren’t only beautiful but also fit well, last long, and make our customers happy. Precision isn’t just our aim; it’s our guarantee!

Assembling Components

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Once all the parts are cut just right, our team of experienced craftsmen starts putting them together carefully. It’s like working on a big puzzle, making sure each part fits perfectly to create your custom door. These skilled artisans focus on getting every detail right, from the hinges to the panels and door frame, ensuring the door isn’t only aesthetically pleasing but also strong and durable.

We use the best tools and methods to attach everything securely. It’s similar to making a piece of art—every nail, screw, and joint is placed thoughtfully by our experienced craftsmen. We’re not just making a door; we’re creating an entrance to your home, ensuring that every aspect shows the quality and craftsmanship you expect.

Applying Finishes

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We now apply the chosen stains or paints, initiating the finishing process that meticulously enhances the natural look or color choice of your custom door. This step is crucial not only for aesthetic appeal but also for the door’s durability, as it protects the wood from weather conditions.

Here’s what we do:

  • Choosing the Finish: We select the best stain or paint that complements the wood and aligns with your desired appearance. This includes considering the option of applying a stain followed by three coats of marine grade epoxy finish, which is paramount for weather resistance.
  • Finishing Process: The application of finishes, whether paint or stain, is a detailed process. After the initial stain or paint, we apply three coats of marine grade epoxy finish to ensure maximum protection against the elements. If you haven’t updated your coat since 5 years ago or longer, definitely get in contact with a door refinishing company.
  • How We Apply It: Utilizing brushes, rollers, or sprayers, we ensure the finish is applied evenly, covering thoroughly to provide a rich, enduring color.
  • Drying and Hardening: Adequate time is allowed for the finish to dry and harden, enhancing its longevity and visual appeal.

We aim for perfection, ensuring your door not only looks excellent but also withstands time and elements!

Delivery and Installation

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After we make your own custom door, our team will take care of delivering it safely and installing it at your place. We transport it in a special box we build to keep it safe and scratch-free. We’ll work with your builder to make sure everything is ready for when we install the door.

When we get there, we start working right away. Our skilled team will be careful with your home, keeping things tidy and not causing much disruption. We work fast but pay attention to details, ensuring your door is installed perfectly and works well. After we finish, we’ll show you the door to make sure you’re happy with it. We do all this to make your entrance look great!


We’ve guided you through the entire process of how custom doors are made, from imagining the best design to making sure it gets to you safely.

By following these steps, you won’t only make your home look better but also have a door that lasts a long time.

So go ahead, open the door to beauty and strength. At Your New Door, we’re here to help you at every step—let’s make your entrance stand out!

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