10 Steps

Step 1. We begin with furniture grade 16 gauge hot rolled steel that has been wiped clean of processing oil and inspected for defects. Then each piece is cut to precision lengths for assembly.

Step 2. The steel is then punched, drilled, rolled and twisted to create intricate and unique designs.

Step 3. All mitered corners and each steel joint is welded at over 1,000 degrees to form a solid piece of steel for structural integrity.

Step 4. After welding, grinders hand-smooth each weld with three different types of abrasives until the joints are silvery smooth.

Step 5. Each door then enters a five-stage wash system where they are degreased, rinsed, phosphated and sealed prior to powder coating.

Step 6. Every door is then sent to a drying oven, then to the powder coat booth where they are grounded and charged and a polyester powder is sprayed to just the right thickness.

Step 7. In the oven, all doors are heated to 425 degrees for a period of 20 minutes to turn the powder to a liquid and allow it to flow. At the same time, the heat triggers a chemical reaction that creates the hard bonding of the particles together and to the treated metal surface.

Step 8. Once out of the oven and cooled each door is closely inspected before moving to final assembly.

Step 9. In final assembly, the doors are outfitted with custom hardware, glass, screens and frames then re-inspected for quality assurance.

Step 10. When doors have passed final inspection they are packaged, wrapped and loaded onto the fleet for delivery to our retail locations.