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The making of a House Beautiful Composite Door

The making of a House Beautiful Composite Door

The making of our New Composite Door Collection

 

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

We believe in going the extra mile for our customers. So while other door manufacturers choose to ship in their door slabs from China, and then cut them to fit, we take our time to make the complete door from beginning to end, following an exact process.

This allows us to offer a better variety of styles and sizes, rather than take a 'one size fits all' approach. And it means we can carefully inspect every stage, from the pressed door sheet and elegant paint finish, to the PAS24 security standard and thermal efficient double weatherproof seals. This process is how we go further to deliver a product that other manufacturers cannot.

Step by step process

Making composite doors - step 1

STEP 1

The process starts with two sheets of fibreglass matting.

Making composite doors - step 2

STEP 2

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

Making composite doors - step 3

STEP 3

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

Making composite doors - step 4

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.

Making composite doors - step 5

STEP 5

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

Making composite doors - step 6

STEP 6

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

Making composite doors - step 7

STEP 7

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

Making composite doors - step 8

STEP 8

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

Making composite doors - step 9

STEP 9

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

Making composite doors - step 10

STEP 10

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

Making composite doors - step 11

STEP 11

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

Making composite doors - step 12

STEP 12

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

Making composite doors - step 13

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.

Making composite doors - step 14

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.

Making composite doors - step 15

STEP 15

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

Making composite doors - step 16

STEP 16

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

Making composite doors - step 17

STEP 17

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

Making composite doors - step 18

STEP 18

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

Making composite doors - step 19

STEP 19

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

Making composite doors - step 20

STEP 20

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

Making composite doors - step 21

STEP 21

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

Making composite doors - step 22

STEP 22

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

Making composite doors - step 23

STEP 23

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

Making composite doors - step 24

STEP 24

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

Our New Door Collection exclusive to Everest

Our New Composite Door Collection

To us, a door is far more than an entrance to your home. It is a stunning first impression designed and built to last a lifetime. With 24 exclusive styles available in 16 elegant colours, our new range of handmade, hard wearing composite doors have been created to give your home an element of unrivalled style.

View Our New Door Collection ❯

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All our products are bespoke, so to provide an accurate quote an appointment is required. Simply fill in the form below and let us know a time that suits you. Partial or full completion of the form will stimulate a follow up to confirm the appointment.

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Get a FREE quote

 

All our products are bespoke, so to provide an accurate quote an appointment is required. Simply fill in the form below and let us know a time that suits you. Partial or full completion of the form will stimulate a follow up to confirm the appointment.

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