Anything the customer prefers. Our niche is millwork made from reclaimed lumber. Our storage yard has 100s of thousand of board feet of lumber in inventory available to pull from, and we will source whatever we need through a broad network if we don't have it in stock. The most common locally available material for us are Northwest softwoods (i.e. pine and fir) salvaged from old buildings. Oak is fairly affordable and commonly available, too. Remember that we are a custom shop, so that means we will find the material that suits the customer. If a customer doesn't want us to reclaimed material, of course we are a full service custom shop that can use any material available.
Sure. We like to keep memories. If for nostalgia reasons you want something special built out of Grandpa's barn, then let's design something around it. Please keep in mind the yield on reclaimed lumber is extremely low. It will take a minimum of twice as much wood as you expect to complete a project. The quality of the wood greatly effects the results and amount of raw material required to make your project. As an average rule of thumb, a door built entirely from barn lumber might need 75 - 100 board feet of raw material before machining to assemble the door. It is especially important to have good boards slightly longer than the height of the door.
A stile and rail door is built with a rigid frame and floating panel. This allows the door to maintain a consistent width and flatness even if the wood moves due to season and environment changes. The entire door can be built from recycled content and all with NAUF glues. All of these doors are fully covered by our warranty. Unlimited options abound for panel design, applied moldings and profiles.
The flush plank doors can give a different look or feel to a project. They basically look like boards edge glued together in one flat consistent plane. There is less decoration, and it is a simpler design. Our flush plank doors can be built with a foam core over the majority of the surface area which allows us to build a lighter or better insulated door. These doors never have recycled content in their core. Typically the most that they will be reclaimed material is about 33% content overall, but everything that shows on the face or edges is matching reclaimed material. The core is usually a combination of engineered materials. Be sure to ask the source, some of these materials we cannot get as a NAUF product. Our warranty excludes coverage on warping in this style of door as is the industry standard. Generally these doors cost slightly less than a comparably sized stile and rail door. If we do not use a foam core product, these doors tend to be heavier than normal. Since there is no panel or rail system, one has more flexibility to apply strap hinges or other decoration anywhere on the surface of the door.
In a reclaimed product the engineered flooring really shines. Since the nature of reclaimed material is rustic with splits, various height, warps and so forth by doing an engineered product we can eliminate those issues. We match the texture and color that you want in the floor but you don't have to put up with the inherent problems that come with installing and living with a reclaimed wood floor. Due to our precise sanding during the lamination process and after, pieces are more consistent in height, more uniform in texture, fit together tighter, no waste, holes and cracks already filled, and no sanding necessary after install unless you want to do a light screen or buff. Engineered is also absolutely essential if installing over radiant heat, concrete, below grade, and wide planks over 6" are more stable. We recommend gluing with floor mastic and nailing our engineered down so it won't have squeaks like some solid wood floors can have. Our specialty is the unusual such as super wide width plank floor that is 12"+ in width; our belief is that it is just not safe to do that with a solid wood floor. Some of our wider width products are actually less expensive than if ordered in a narrower width.
We personally do not care for prefinished flooring due to installation problems associated with it, so our product requires site applied finish. This means that your floor finish if site applied will be easier to sand and refinish than a prefinished floor. Also you do not have to deal with that micro bevel groove between each board that tends to fill up with dust and crumbs.
Engineered flooring is more expensive. Our product has a thicker wear layer (6mm) and is thicker overall (18mm) than the industry standard. This means that is equal in thickness to a solid wood product and can be sanded/ refinished just as many or more times than comparable solid wood floors. We use an exterior grade, FSC pure, 9 layer, NAUF Carb 2 compliant plywood along with a type II water resistant crosslink PVA Glue. What this means to you is our flooring has no odors, tough, water resistant, and qualifies for a multitude of Green building programs such as LEED with the USGBC. Due to all of the advantages, durability, ease of install, and ease of finishing/sanding, we believe the difference in price over a solid product is worth it. If you are comparing the two different products we will be frank with you and tell you whether it is worth the extra money for your application.
Complete with clearance and room for the wheel to spin one needs 1 7/8" space over the top of the door to fit the complete track system. This is the distance over the top of the door itself, not over the door opening. Therefor if one puts a floor guide under the door and needs 1/2" gap for that then if the door is 2 1/2" shorter than the distance from floor to ceiling that is more than enough room to fit everything.