The making of a Composite Door

How Composite Doors are made

We're proud of the fact that every one of our exclusive doors is carefully and precisely handmade in the UK.

Everest Composite Doors all handcrafted in Britain

British handmade precision

At Everest, we produce our doors from start to finish in our factory in Wales.

Other door manufacturers choose to ship their door slabs from abroad and then cut them to fit. We are proud to construct our doors in a UK factory that has a family atmosphere.

Apart from supporting the local community, making our own products means we have control from end to end. We can offer a better variety of styles and sizes, rather than take a 'one size fits all' approach.

We carefully inspect every stage, from the pressed door sheet and elegant paint finish to the PAS24 security standard and thermally efficient double weatherproof seals. This process is how we go further to deliver a product that other manufacturers cannot.

Step-by-step process

STEP 1

The process starts with two sheets of fibreglass matting.

STEP 2

The sheets are carefully placed on the aluminium door leaf mould.

STEP 3

The sheets are combined with resin and heated under pressure to create the outer and inner door leaves.

STEP 4

The pressed sheet is peeled from the aluminium door mould to create a precise replica of the wooden door with enhanced decorative graining.

STEP 5

The newly pressed sheets are then inspected and the grain on the mould is verified.

STEP 6

The double rebated inner frame is machined to size and the corners are welded.

STEP 7

The inside pressed sheet is married to the welded inner door frame manufactured to the precise customer door measurements.

STEP 8

The inner and outer pressed sheets are then adhered to the 70mm double rebated frame forming an inner void.

STEP 9

The frame is then pressed to ensure the frame and leaves bond fully.

STEP 10

The inner void is filled with insulating foam before undergoing a curing process.

STEP 11

The oversized leaves are cured without pressure before undergoing the next step.

STEP 12

The panels are precisely machined to size on the CNC machine.

STEP 13

All apertures for windows, letterboxes, handles or locks are precisely machined into the panel at this stage. The double rebate is also machined.

STEP 14

The precisely sized panels are painted to the customer's choice of colour. Particular care is taken to ensure the deep grain is enhanced.

STEP 15

The painted panels undergo a full inspection before the paint fully cures to ensure full coverage and grain enhancement is achieved.

STEP 16

Following an infrared bake, the panels are hung to fully dry the paint finish.

STEP 17

Whilst the panels are curing, any decorative glass panels required are precisely created in the Glass Studio.

STEP 18

If sandblasted opaquing is required for privacy or to incorporate house names or numbers, individual glass panes are created.

STEP 19

The triple glazed sealed units are created, incorporating decorative glass.

STEP 20

The triple glazed units are sealed before being filled with insulating Argon gas to enhance thermal efficiency.

STEP 21

The sealed units, hinges and door furniture are added to the coloured panel to form the finished door.

STEP 22

The door is hung, tested and inspected precisely to exacting standards.

STEP 23

The finished door is wrapped for protection before leaving the factory to installation depots throughout the country.

STEP 24

Your beautiful new door is delivered and installed for you to enjoy.

Everest Door Reviews

We've made and fitted millions of front doors

We offer 40 stunning door colour choices for you to find the perfect colour for your front door. We also offer dual colour doors so you can have a different colour inside and out.

COMPOSITE DOORS