Cabinet Doors Manufacturer For Over 30 Years
The Door Stop started making custom cabinet doors in 1980. We only offered 4 styles and those were only available in Red Oak. Back then the majority of Cabinet Shops made their own doors and, because we only offered 4 door styles, our market was very small.
Over the next 30 years we invested in ever more modern manufacturing machinery that allow us to produce doors with tolerances that were unachievable a few years earlier. This new computerized manufacturing machinery allowed us to produce doors with sizes so exact that cabinet makers, with their tape measures, considered nearly perfect.
Our components are all cut with computerized machinery to accuracies measured in the thousandths of an inch and our cabinet doors, when completed, are guaranteed accurate to within 1/64 inch, or about 15-thousandths of an inch.
Because cabinet makers realized that offering this level of sizing accuracy would increase their business, more and more custom cabinet shops started buying their doors instead of making the doors themselves. This increased volume from the cabinet shops allowed us to actually increase our investment in automated machinery. The result has been our ability to manufacture a custom cabinet door with sizing accuracy that no cabinet maker can consistently produce. We were also able to introduce new cabinet door designs, and today we offer hundreds of different door styles in every domestic wood type available. In fact, considering all the optional door styles, wood types, panel designs, stile details, outside edges, cope & stick and mitered, arched and square, etc...the possible cabinet door permutations come to millions of possible different cabinet door designs.
This possibility of offering so many designs has convinced the vast majority of custom cabinet shops to buy their doors instead of making their own. Outsourcing the doors also frees up labor for other tasks and avoids the increasing cost of machinery needed to produce the product. Over the last decade, as door machinery has become computerized, machinery costs have increased dramatically. With the costs of producing superior quality cabinet doors in volume exceeding several million dollars, it no longer makes economic or business sense for a cabinet maker to even consider making his own doors.
The Door Stop is constantly adding new equipment and this year is no exception. Two new triple-head widebelt sanders have been added along with computerized coping machinery and computerized mitering equipment. We are also adding new Mitered Door sanding capability. Our investment in our factory and equipment exceeds ten-million dollars and is growing every year.
We believe that it requires the very best modern manufacturing machinery to consistently produce a superior product at serious volumes and our commitment is to continue to grow and invest into the future.
Cope & Stick Cabinet Doors
Today's popular cabinet doors can be grouped into two major categories, and dozens of sub-categories. These two major categories are Cope & Stick and Mitered.
Cope & Stick doors can be recognized by the design of the doors frame. The Stiles (the left and right--vertical-- pieces of the frame) extend from the door's bottom to the top. The Rails (the horizontal pieces of the frame)
Possibly the most recognizable Cope & Stick door is the Shaker Cabinet Door. The Shakers had a design philosophy that still holds true today.
“Don’t make something unless it is both necessary and useful; but if it is both necessary and useful, don’t hesitate to make it beautiful.”
Following that philosophy, Shaker Cabinet Doors consist of a simple square frame with an inset panel. The door has no inside or outside profile on the frame pieces and no grooves or profiling on the panel. A very simple, yet functional design that still lives on today.
This picture shows a typical Cope & Stick joint.
Most popular Cope & Stick doors today go well beyond the simple Shaker style. Today's Cope & Stick doors can be built with any one of several hundred possible details on the inside and outside of the frame. They can have Inset Panels, be Glass Frames without panels, or have Raised Panels with dozens of Panel Profiles to select from.
Cope & Stick doors, sometimes referred to as Traditional Cabinet Doors, can be manufactured in almost any wood type. The Door Stop limits our wood selection to woods certified by the Forest Stewardship Council (FSC) as being sustainably harvested.
Today's Cabinet Door Market consumes slightly more Cope & Stick doors than Mitered Doors, but the Mitered Cabinet Doors have been steadily gaining market share in the United States.
Mitered Cabinet Doors
Our line of Mitered Doors is much more extensive than our Cope & Stick line. The reason being that we offer ten Cope & Stick Stile-cuts and 86 Mitered Stile-cuts. When multiplying the 86 Stile Cuts with the different wood types, the list of Panel Cuts, and the Possible outside edges, you have over three-million possible Mitered Door design combinations.
This huge number of door design possibilities is one reason for the growth in the popularity of Mitered Cabinet Doors.
This picture shows the Miter joint on the 3-inch SC602 detail of our Delaware Mitered Door, machined with our computerized equipment.
Another reason for the growing popularity of Mitered Doors is the evolution in equipment used to machine the miter joint. Our machinery uses computer control to cut an exact 45-degree miter then actually machine the hidden mortise and tenon into the stiles and rails. This method produces a perfect miter with the tightest miter joint in the industry. The machined mortise and tenon eliminates the need for biscuits or dowels and provides a much larger surface area to produce a glue joint which is far stronger than other joining methods.
Our Mitered Cabinet Doors are available in all sustainably harvested Domestic woods and will be produced in under 10 days.
Over the past 10 years, we have manufactured and shipped several million doors into all 50 states, Canada, Mexico, and 17 other countries.