Our Multi-Layer Custom Finishing Process for Wood Doors
Our exclusive, multi-layer exterior finishing process integrates cutting-edge water-based technologies with exacting application techniques to produce a finish that is as beautiful as it is resilient. This proprietary process is meticulously engineered to highlight the natural elegance of the wood while providing unmatched protection against harsh outdoor elements.
At US Door & More Inc., we take pride in our custom-formulated finishing process, crafted specifically to meet our exacting standards of durability and aesthetics. Unlike generic, off-the-shelf products, our finishing materials are the result of an intensive collaboration with leading materials specialists, designed exclusively for our doors. This unique formula represents a higher standard in wood finishing, specifically optimized for peak performance and tailored to the distinct needs of our exterior products.
Each layer is a testament to our commitment to quality, crafted to not only enhance the visual appeal of our doors but to ensure they stand the test of time. This exclusive formula embodies our dedication to innovation, craftsmanship, and the enduring beauty of natural wood.
Step 1: Repairs and Sanding
Objective
To achieve a smooth, even surface, free from imperfections, ensuring an optimal base for subsequent treatments.
Process
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Repairs are made to any surface imperfections, such as cracks or knots.
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The wood is sanded with 150-180 grit sandpaper, preparing a flawless surface.
Step 2: Water Treatment to Open the Wood Grains
Objective
This step involves a fine mist of water applied to open up the wood's pores, which facilitates deeper, more uniform stain penetration.
Process
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A light misting opens the grain, allowing for enhanced stain absorption.
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The wood is allowed to dry briefly before moving on to the next step.
Step 3: Water-Based Impregnating Stain for Hardwoods
Description
This stain provides a penetrating layer that enhances the natural color of the wood and offers UV protection. Specifically formulated for hardwoods, it reduces tannin bleed and prepares the surface for additional layers.
Technical Specifications
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Specific Gravity: 1.015 ± 0.010 g/cc at 68°F
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Density: 8.47 ± 0.010 lbs/gal
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Weight Solids: 13.5% ± 1%
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Volume Solids: 10.84% ± 1%
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Viscosity: Approximately 20 seconds Zahn cup #2
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VOC (Material): 0.25 lbs/gal (30.45 g/l)
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VOC (Coating): 1.67 lbs/gal (199.70 g/l)
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Coverage: 113 sqft/gal at 1-mil dry thickness
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Drying Time: Dust-free in 60-90 minutes; ready for overcoating in 4 hours
Performance
This stain is available in custom colors, each with iron oxide pigments for enhanced UV protection. It deeply penetrates hardwoods, improving resistance to environmental wear and fading while showcasing the wood’s natural grain and beauty.
Step 4: Sanding and Touch-Up Process
Objective
Refining the stained surface for a smooth finish and correcting any minor imperfections to prepare for the sealer application.
Process
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Sanding is done with fine grit sandpaper to remove any raised wood fibers.
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Any touch-ups needed are performed to ensure a consistent color and texture.
Step 5: Clear Water-Based Exterior Sealer
Description
Our water-based sealer serves as an essential foundation, providing chemical resistance, elasticity, and a robust barrier that prepares the wood for the final topcoat.
Technical Specifications
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Specific Gravity: 1.04 ± 0.100 Kg/l at 20°C
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Density: 8.65 ± 0.100 lbs/gal
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Weight Solids: 31.9% ± 1%
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Volume Solids: 29.05% ± 1%
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Viscosity: 30 seconds DIN6 (approximately 30 seconds Zahn cup #4)
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VOC (Material): 0.60 lbs/gal (71.48 g/l)
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VOC (Coating): 1.63 lbs/gal (195.33 g/l)
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Application Amount: 150-180 microns per coat
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Drying Time: Dust-free in 1 hour; scuff sandable in 1-2 hours; stackable within 12-16 hours
Performance
This sealer enhances moisture resistance and provides an elastic foundation to accommodate natural wood movement. It also improves the adhesion and longevity of the topcoat, fortifying the door against environmental stresses.
Step 6: Sanding and Touch-Up Process
Objective
Further smoothing and touch-up work to perfect the surface before the final topcoat application, ensuring the sealer layer is even and ready for a flawless finish.
Process
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The sealer layer is lightly sanded to ensure a smooth, even surface.
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Additional touch-ups are made as needed to ensure consistency and uniformity.
Step 7: Satin Water-Based Exterior Topcoat
Description
The topcoat provides a durable, protective layer with a satin finish, enhancing both the appearance and the resilience of the door. This final step locks in the previous layers and provides UV protection, moisture resistance, and flexibility to withstand temperature fluctuations.
Technical Specifications
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Specific Weight: 10.320 ± 0.100 lbs/gal at 68°F
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Weight Solids: 42% ± 1%
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Volume Solids: 41.8% ± 1%
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Viscosity: 28,500 ± 2,500 mPa.s
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VOC (Material): 0.26 lbs/gal (30.75 g/l)
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VOC (Coating): 0.25 lbs/gal (30.20 g/l)
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Coverage: 330 sqft/gal at 1-mil dry thickness
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Drying Time: Touch-dry in 1-3 hours, fully cured in 12 hours
Performance
This satin topcoat provides exceptional UV resistance with built-in absorbers, enhancing the wood’s color and protecting against fading. The topcoat’s flexible and resilient properties make it highly durable, preserving the finish and structure of the door even in variable weather conditions. The satin sheen adds a sophisticated look, elevating the natural beauty of the wood while providing long-lasting protection.
Comprehensive Application Process
Our multi-layer finishing process ensures each door is treated with the utmost precision, resulting in a highly durable and visually striking finish. By combining advanced water-based technologies with precise sanding, sealing, and topcoating steps, we deliver a product that stands up to the elements while showcasing the inherent beauty of the wood.
