Comparing Solid Wood Doors vs. Solid Core Doors

Craftsmanship, Quality, & Durability Leading Factors Behind Contractors & Homeowners Choosing Solid Wood Doors

Solid wood doors are manufactured with 100% natural wood and assembled with panels and solid boards and are a step above solid core doors or wood look powder coated finishes, which respectively are constructed with either a real wood laminate over an MDF (medium density fiberboard) core, or a synthetic spray coating over any material including metal. While there will always be a demand for modern materials in architectural and design applications, many homeowners still find themselves drawn to timeless classics and weighing the benefits of solid wood doors vs. solid core doors. When building a new home or remodeling a recently purchased one, hard decisions are made over appliances, fixtures, lights, flooring, carpet, tile, and trim. However, a consistently overlooked aspect of the home design that provides tangible benefits and enhanced aesthetic appeal is interior and exterior doors. Again, choices abound regarding the style, color, shape, and functionality of these doors however when comparing solid wood doors versus solid core doors, the decision is quite clear.

At Allegheny Wood Works, we believe that the decision is far simpler than it may appear. An investment in solid wood doors for your home not only offers exceptional aesthetic versatility but superior structural integrity and insulating properties. Allegheny Wood Works combines old-world style craftsmanship with modern technology to offer real solid wood doors in custom designs at cost-competitive pricing. This article will discuss the history of solid wood doors, the expansive catalog of doors available from Allegheny Wood Works, the features of solid wood doors, and the countless benefits homeowners can expect from installing these hand-crafted doors throughout their homes.

Solid Wood Door Products

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History of Solid Wood Doors

Since the dawn of civilization, humans have found ways to protect their dwellings from predators and harsh weather. These first rudimentary barriers were likely comprised of the same materials used in solid wood doors today. The use of doors to separate living spaces can even be traced back to ancient civilizations like Egypt and Mesopotamia. In those early eras of humanity, solid wood planks occasionally reinforced with metal provided sufficient protection against the elements. Craftsmanship capabilities expanded in the subsequent centuries to offer hinges, handles, locking mechanisms, and more advanced door shapes but the base material remained relatively unchanged as solid wood was widely available. As exploration of the globe widened societal understanding of available materials, new species of wood were incorporated into the designs and afforded improved durability and aesthetic appeal. Elegantly crafted doors became a status symbol and many of these impressive creations still exist in churches, mansions, and various estates throughout Europe.

In more recent history, the vast expansion of the human population required significant housing where affordability became the primary concern. As a result, solid wood doors were eschewed in favor of composite materials, hollow construction, and even metal alternatives found in solid core doors. As many of these homes have now changed hands, new owners are looking to replace the existing barrier with a stylish and durable solid wood door that matches the design of the home. Not only that, but concerns regarding sustainable practices and insulating properties have once again brought solid wood doors into the spotlight for interior designers, DIY projects, and architects versus solid core door alternatives. Allegheny Wood Works is proud to be a part of revitalizing the premium craftsmanship of solid wood doors and looks to be a significant contributor to the next chapter of history for this product.

Solid Wood Door Components

The largest difference between solid wood doors versus solid core doors is that you won’t find any thin veneer sheets glued to particle board in our facility. Allegheny Wood Works is proud to combine a history of old-world style craftsmanship with modern technology and equipment to manufacture quality custom solid wood doors. Many of the benefits associated with solid wood doors are a by-product of the fabrication process implemented by Allegheny Wood Works and include several key construction features not found in solid core doors. These design features and their imparted improvements are listed below:

  • Engineered Side Stiles: Side stiles are the vertical components that comprise the right and left-hand sides of the door itself. The solid wood construction reduces concerns customers may have over scratches, knicks, and possible sand throughs during finishing. Thanks to the engineered construction of the side stiles, they are far less likely to bow or twist than the lower-quality particle board and veneer combination used by other companies.
  • Solid Rail Construction: Door rails and center stiles are any vertical or horizontal components that join together with the stiles to form the overall door structure. Allegheny Wood Works glues two boards together to create all center stiles and horizontal rails for our solid wood doors. This manufacturing practice ensures minimal warping or movement while providing an enhanced aesthetic appearance.
  • Cope & Stick Tenon Joints: Precision cut joinery is an essential facet of craftsmanship for solid wood doors. Cope and stick tenon joints are frequently used in door construction and the production of cabinets or furniture. Allegheny Wood Works uses high-tech tooling and modern equipment to create gap-free and structurally strong cope-and-stick tenon joints to adhere stiles and rails together.
  • Double Secure Top Rail Joinery: Not only are the stiles and side rails adhered by cope-and-stick tenon joints, but the top rails are double secured. The top rail for each solid wood door manufactured by Allegheny Wood Works is double-secured with steel reinforcement anchors or wooden dowels. The additional security for this part of the door structure helps to compensate for the added pressure placed upon the top rail when hanging.
  • High Quality Foam Expansion Inserts: Wood is far from a perfect building material and can experience significant expansion or contraction through normal use. Thankfully, we have considered this when designing solid wood doors. To compensate for this added movement, our designers have included high-quality foam inserts into the section of the stiles and rails where a panel will eventually be inserted. This foam compresses and expands with the wood and prevents panels from cracking or rattling during use.
  • Solid Wood Panel Construction: In addition to the rails and stiles, all panels are manufactured from solid wood. All panels in solid wood doors from Allegheny Wood Works are edge-glued solid boards that offer impeccable beauty and a minimized possibility of cupping or cracking years after installation. All raised end grains are thoroughly sanded before final installation to further streamline the finishing process.

All of these manufacturing processes combined with true solid wood material construction result in doors that provide enhanced security, longevity, and aesthetic appeal to customers. Customers of Allegheny Wood Works can expect to see all of these construction practices in their solid wood interior and exterior doors.

Solid Wood Doors Vs Solid Core Doors – Pros & Cons

When considering which type of material you’d like for the interior and exterior doors of your project it is important to compare solid wood doors versus solid core doors. All components of a solid wood door are fabricated from a variety of natural wood species whereas a solid core door has an engineered non-natural wood core with a fine wood or veneer “skin” that resembles natural wood construction. This section lists the pros and cons of each material style and can help contractors, designers, or do-it-yourself project tacklers understand the pros and cons of each.

Solid Wood Doors Pros

  • Can include custom designs, carvings & profiles
  • Good sound-blocking characteristics compared to hollow core
  • The ultimate standard of luxury
  • Can be modified after manufacturing to fit opening height and width
  • Exceptional durability and minor damage can be repaired due to the thick solid wood construction.
  • Resistant to moisture and preferable for exterior use

Solid Wood Doors Cons

  • More costly than solid core or hollow core doors
  • Slightly lower sound-dampening characteristics

Solid Core Doors Pros

  • Slightly less costly than solid wood for basic designs
  • Improved sound-dampening characteristics

Solid Core Doors Cons

  • Less durability and resistance to damage
  • Surface scratches may not be repairable due to the thin layer of veneer
  • Susceptible to swelling from moisture exposure
  • Since the laminate layer is thin, carved designs are not usually possible
  • Modifications to height and width are limited to the thickness of the solid border insert

Solid Wood Door Profile Options

The design potential for solid wood doors with Allegheny Wood Works versus lower-quality solid core doors is limitless. All standard door designs offered by Allegheny Wood Works apply to both interior and exterior door installations. Our team prides itself on offering quality builds, durable, and beautiful interior and exterior solid wood doors to complement all home designs and color schemes. If you do not see the specific style or profile of the door you are looking for, our facility can accommodate most custom design specifications. Additionally, you can contact our sales department for a quote. Below is a list of our available profile options that enhance the overall design of interior and exterior doors:

  • Raised Panel: Available for both interior and exterior front entry installations, raised panel doors are an excellent example of old-world craftsmanship as these doors have existed for hundreds of years to combat the detrimental effects of moisture on solid wood doors. The panel design is free to expand and contract with seasonal fluctuations in humidity and temperature without compromising the shape or frame integrity.
  • Flat Panel: Flat panel solid wood doors are suitable for interior and exterior applications and can also be referred to as Mission Doors or Arts and Crafts Doors.
  • K-Brace: Suitable for interior doors, the K-Brace profile can add a unique or rustic look to any home and is instantly recognizable due to the “K” appearance of the brace as it overlays the panels.
  • V-Groove: V-Groove profiles can be incorporated into any solid wood door design and are designed to simulate a plank look for mission or raised panel doors.
  • Louvered: The louvered profile for solid wood doors can be either framed louvers or flush louvers depending on the project specifications or home design. Louvers can serve as a replacement piece for standard panels in any of AWW’s door designs except for arched panels. Not all wood species may be available for this profile.
  • Transoms: Used to separate doors from windows or decorative accents, transoms can help provide additional light or ventilation to interior rooms. These can be manufactured to match the specific wood species or design of the installed door.
  • Applied Molding: Used in mission door designs, applied molding around the edges of a flat panel is an excellent way to add depth and elegance to the design.
  • Dutch Doors: Available for interior and exterior installations, dutch doors are divided horizontally so that the bottom half remains closed while the top half opens. Additional design modifications by Allegheny Wood Works allow for both halves to open or close in unison.
  • Flush Doors: Solid wood flush doors are suitable for interior and exterior entry applications and feature a plain flat face on both sides. Flush solid wood doors are commonly used in locations emphasizing contemporary design and can help draw attention to other elements in the space using specific wood species or optional wood stains.
  • Engraved & Carved: Allegheny Wood Works offers customers the option to engrave designs into custom solid wood doors through laser engraving or CNC router carving methods. Custom engraving and carving services are available for all interior and exterior doors.

Real Wood Specie Options for Solid Wood Doors

The true beauty of solid wood doors is that no two pieces are alike. Slight variations in color, grain, and texture create the lasting aesthetic appeal of solid wood doors versus solid core doors that attempt to replicate natural patterns and hues but fall short. Allegheny Wood Works is proud to offer an expansive selection of wood specie options for custom solid wood doors. The light tan to deep red, the varying colors or patterns can evoke different levels of warmth and elegance to match any interior or exterior design.

All the popular wood species variants are readily available for our customers to select for their custom solid wood door requests. These can include pine (white or knotty white), oak (red oak, rustic red oak, white oak, and rustic white oak), and maple (soft, hard, pacific coast, rustic). Additional wood specie variants available for custom solid wood door projects with Allegheny Wood Works are listed below:

  • Alder & Rustic (Knotty) Alder
  • Ash
  • Birch (Natural)
  • Cherry, Rustic Cherry, Sappy Cherry, and Brazilian Cherry
  • Cypress
  • Hickory & Rustic Hickory
  • Mahogany (African & Sapele)
  • Poplar
  • Spanish Cedar
  • Walnut

Advantages of Solid Wood Doors vs. Solid Core Doors

The features and advantages of solid wood doors versus solid core doors, especially when fabricated by the experts at Allegheny Wood Works, are extensive and offer exceptional returns on investment. From an individual installation of an exterior solid wood door to outfitting an entire commercial building, every project completed with these hand-crafted doors can experience the benefits listed below.

  • Durability & Strength: There is no question that a quality solid wood door offers superior strength and durability over solid core doors. The varying hardness levels and densities of wood species provide customers with immense flexibility to increase durability for exterior installations without compromising the aesthetic beauty that makes these products so appealing. With proper maintenance and care, Allegheny Wood Works doors can withstand years of exposure to harsh weather conditions.
  • Soundproofing & Noise Dampening: Solid wood doors are exceptional options to improve noise dampening and soundproofing measures inside homes and buildings. The density of solid wood, especially hardwoods, helps reduce soundwaves through absorption. They can limit the reach of outside noise and inhibit sound traveling from room to room inside your home. Home offices, bathrooms, and bedrooms can all benefit from the noise-dampening properties of solid wood doors.
  • Insulation: Avoiding heat transfer is crucial for homes and businesses no matter the climate. Solid wood doors possess a higher R-value than hollow core or composite material doors meaning they provide better insulation. There may be slight variations in the R-value depending on the specific species, but across the board, these doors offer improved insulation to help maintain desired internal temperatures and humidities.
  • Versatile Aesthetics: When you combine the available wood types, shapes, and profile configurations of solid wood doors, it is hard to match the sheer versatility of this material. Additionally, the receptiveness of solid wood to supplemental finishing techniques like staining or painting makes them incredibly customizable and can be made to match nearly any design theme or color palette.
  • Long-Term Value: With proper maintenance a quality solid wood door can last a lifetime or beyond. Although initial costs can sometimes be higher than competing materials or designs, these doors offer purchasers a quick ROI between energy savings and the increase in value they bring to your home or business.

Expert Finishing of Solid Wood Doors

For many of our customers and projects, a solid wood door will require supplemental finishing before final installation. Allegheny Wood Works is proud to offer factory finishing with Sherwin Williams products, including standard and custom solid wood doors. With available color-matching capabilities, we can closely match submitted samples so that new doors match existing designs.

Allegheny Wood Works finishing procedure for solid wood doors includes one coat of optional stain and two supplemental coats of premium quality catalyzed lacquer that can be gloss, medium rubbed effect, or dull rubbed effect. This finishing process further protects the beautiful grain and natural color of the wood and preserves its appearance throughout its lifespan. Not only that, but the right stain can further highlight the natural wood grain color or pattern and provide customers with the added pop of color or elegance they are looking to incorporate into their home design. Allegheny Wood Works offers the below standard Sherwin Williams stains:

  • Autumn Oak
  • Cordovan
  • Fruitwood
  • Wheat
  • Cherry
  • Dark Oak
  • Golden Hickory
  • 80/20 AWW Blend
  • Cinnamon
  • Dark Walnut
  • Mahogany
  • Traditional Cherry

Handcrafted Solid Wood Doors from Allegheny Wood Works

Since 1997 Allegheny Wood Works has consistently evolved to incorporate modern manufacturing practices into solid wood door production without diminishing the old-world style craftsmanship that makes these products so sought after. By controlling each step from lumber sourcing through high-quality suppliers to the final finishing process, we are confident that the quality of our doors for interior and exterior applications far surpasses that of solid core doors. As more and more Americans rediscover the durability, beauty, and versatility of real solid wood doors Allegheny Wood Works is poised to remain an industry leader. Our facility is flexible enough to handle custom project submissions for a single exterior door up to large quantity purchases of interior doors to outfit an entire building. To learn more about Allegheny Wood Works solid doors or get started on a quote for your project, reach out to our highly qualified team today!

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