We think, biggest the tree, the most matured it is, which is true but, not all the time. When users lose confidence on nonprofessional manufacturer, for producing low quality door and frame production, they get confused and angry. Problem with door doesn’t take place right way with door and frame, sometimes trouble starts after 6 months or so. Most of the time users don’t have the pleasure to have a solution to their problems, since the problem starts after a long time, when the problem starts they want to complaint but, don’t find anyone to do so, may be it is too late, people who they have purchased the door from went out of business, moved his business to somewhere else, or don’t want to take the complaint because it is too late for that, or you didn’t pay me enough to complain or there is no warranty or guarantee I have given you, or I don’t remember you. These are the common practices with the local manufacturers, they know it very well, these people are going to have problem after 6 months or so, they care less about what happens after so long, they can’t have long term business plan. There are few genuine manufacturers who will take a very good care of you, they are professional people, they know the areas where the quality and matured timbers are available, section and saw them right, season them properly using kiln dry chamber to make sure the lumbers are seasoned properly, bring the moisture content to 14 percent, which is appropriate for Bangladesh, for other part of the world it could be anywhere between 11-14 percent. Since these people are professional and they care about their business, they are the ones will manufacture them properly and they know and will maintain the high quality, have a genuine warranty, guarantee to provide you the desired services you want for your hard working money. These manufacturers are trying to reach you to get your attention, you need to educate yourself to learn and identify these quality people, otherwise you have to keep on getting disturbed and losing money. You may visit www.woodworldbd.com and study on everything about wood, don’t need to stay in the dark anymore, this will benefit both of us.
Fighting this kind of situation consumers get frustrated, and at last they want to produce door in their own care with the help of a carpenter, now you know what happens after that. Carpenters will advise them: no worries, we will collect quality timber, the original mahogany from Jessore, matured and the very best timber will make the best door you have ever seen and will, season properly and manufacture the perfect door in the world and will last for generations. If you purchase door or frame from any manufacturer, they wouldn’t last very long, they season the timber mechanically and destroy the temper of the timber and they will bend and crack, so many other things they say to convince you, just to get the job to make some money to make a living. Next thing they do is take some money from money from you as an advance to purchase the timber, and will disappear for a while, will come back when you are about to lose your temper, because you need them now, you already have rented your apartment an people are going to move in soon, no time to season and manufacture and so on, but you are angry. Whose fault is that?, Yours or mine?
Things are changing over the time and people are trying to understand, they are learning about timber, quality, and quality manufacturing. We are inviting hundreds of civil engineers and showing them our seasoning chamber, teaching them how they work, showing them our production techniques, how precisely our special machines are making the parts of the door, to help the consumers, the engineers and our business. Civil engineers don’t have enough knowledge about wood technology to advise the home owners, I welcome them to read the articles in my website and learn, visit my industry and learn how the quality doors are made and help to understand the building owners, help our business and make good money, which is legal.
I have spent a lot of time researching and manufacturing the machines and put to work, I am educating the civil engineers about quality timber, Kiln- Dry chamber and quality manufacturing. Telling them, this is one of the most important sectors in civil engineering, they need to learn.
There is a lot of good real estate company, have taken bad names due to their civil engineer’s lack of knowledge in this field, it’s not their fault, I have asked them, answer was, they have barely touched this subject, not enough to help anyone with this limited knowledge, I am teaching 10/15 of them every morning for free of charges, for my age this is very hard job for me but, I am trying, and will continue trying to educate them, for my own benefit, and at the same tine help the home owners and the real estate owners, I found the engineers very smart, sharp and very much interested to learn about wood. Engineers those who are interested to learn deeply about wood technology, I have advised them to go to my website and study and take a test, if they pass I will give them in writing what they have learned, they can help the home owners with this skill, this is free of charge.
Engineers those who don’t have a job, I am putting them to work, with a certain commission and hire the most active ones permanently and put them to work, those who are not student, advise them to be honest, hardworking and dedicated.
Production is a sequence of machine work in this field; there are some manual work still need to be done, due to the shortage of space and which we are trying to resolve shortly, to increase our production capacity and better quality.
First thing we need to do, is to find out whether the rough lumber we are using is straight, if not we are using a especial kind of machine to make it straight, lumber straighten machine, which is done by heat and pressure, before we put through our 4 side planer, we put the lumber through a metal detector for a test, to make sure if there is any nail or a piece of metal inside the lumber, which may damage our diamond cutters. After we have done with the test, we pass the lumber through 4 side planer to jointer 2 side and thickness the other 2, four side planer is adjustable to cover any size in a limit, which is within our requirements. Bottom and left side of the machine work as a jointer, top and right side part of the machine work as a thickness-err, if we had to do it using manual jointer and thickness-err machine, which would be very time consuming and laborious, production capacity will be slow, this machine is the base of entire production capacity. It is capable to plane 7’ long lumber in 30 seconds. Now the lumbers are properly sized to our requirements.
Next is the cutting, we need the lumbers in different length, the different length of sizes will need to cut precisely using a 2 way 90 degree sliding cutting machine, where the table slides with the lumber, where the lumber will be mounted to the table by a variable adjusting guide and which can be adjusted to different length of cut. Pieces of timber need to be cut to a precise length, the guide is very accurate and adjustable to micrometer. If wooden pieces aren’t cut in precise length then it would be difficult to assemble the door right, it got to be precise, otherwise door wouldn’t fit right and a little deviation in length may cause a big problem in the whole structure of door.
For door manufacturing, next machine is the tenor machine, this is a medium size machine to cut the tenor part of the door piece, which cuts in a single pass, starts with double circular saw blade to saw the tenor part from the top and the bottom, then two small circular saw blades are used to cut those two sawn pieces off, and then two diamond made and sharped especial blades will make the female engrave to the top and the bottom and shave off the tenor male part to accurate measure to fit into the mortising part leaving a little glue gap. We need to do one or both end.
Next step is the double side auto bit cutter, which will cut bits in the precisely sized lumber, one side from the top and the bottom in a single pass, all this action takes place in an instance, it has a built in very powerful feeder, which feed the lumber smoothly and evenly, to make sure there is no bump in the bit. We need 3 different kind of bit cutter machine for different length and pattern, one to cut bits for shorter parts, other one for long, will cut one side at a time, and the other one will cut the curved or round woods only. The machine is called the round bit cutter, takes a lot of skill to operate, which is risky too; we have done everything we could to make the machine safe to operate.
Panel cutter, is the next step for door manufacturing, we need two machines to get this job done, one is for squire panes, which is auto feed and the other one for round and curved and operated manually. The manual panel cutter is also risky to use like the round bit cutter. They cut the top and the bottom of the panel in a single pass, where one cutter sits at the top and the other one at the bottom of the machine revolving shaft to cut the panel in a single pass. The blades of the machine is set measuring the gap of the bit cutter, and usually measured .10 mm narrower, so it will fit in the bit cutter’s groove easily, and the little gap will ensure the panel to move, during the change in weather which cause a little deviation in the length and the width, which may cause the panel to move.
Next thing we need to do is to mortise the lumber, where the tenor part will fit to the stile or rail part of the door.
It is important to note that, the main two vertical parts on two sides of the door is called stile, is the back bone of the door, any part in the door installed vertically beside two stiles is called sub-stile, where the panels are installed. One part at the very bottom and one at the top is called the rail, others parts running horizontally, anywhere inside the door, where panels are installed is called sub-stile. All the stiles, sub-stiles, rails and sub-rails are connected together to form the main structure, the panels are inserted between them and the basic door is understood. We mast stamp them together with a wooden plaque, and water resistance wood glue, Favicon.
Tenor, mortising and panels are made so uniquely to make sure, there is little gap for wood glue to create the strongest bond between them. The panels are inserted between the stiles and rails leaving a little gap, about 1mm in each side for expansion and contraction, due to weather change, which may cause prevent the door from getting expanded in the rainy season and contracted in the summer.
Each piece of lumber has we use to make the door, has matured and immature side, each of the pieces has to be used in such a way, all the mature side of the lumber has to face in one side of the door, otherwise the door may bend in such a way that, the top
and the bottom part of the door may come out of the frame, and make a disaster in manufacturing maturity. We need to identify matured and immature face of each lumber and mark it with a pencil so the stain wouldn’t be permanent. While we are doing the tenor or cutting the bit, the immature part will stay at the top all the time. When we install the door with the frame, the immature side of the door has to face the entrance side of the room. Since all the immature face of each lumber is facing one side of the door and the matured side is facing the other, the door will have a tendency to bend comparatively to the immature side, since the immature side of the door is pressed in to lock all the time, so the door will always have a pressure in the lock, and which will naturally put a pressure to the door from preventing from bending and after a long time it will stay straight and it will never bend out of the frame, which is the worst part.
Before we assemble the door, always finish both side of panel doors passing thorough an oscillating drum sander to smooth out the panels, then we assemble the door and finish the entire door passing it through a larger size oscillating drum sander, where the panels are usually little down than the rail and stiles so, the drum sander will shave off the top and the bottom part of the door to a desired thickness, which was initially left 3 mm over for the final finishing and have been maintaining 1.5”+.
We have developed and manufacture a machine and named it back to back abrasive brush sander, we didn’t put in the production yet, which will finish one side of the door in a single pass, in 60 seconds, one complete door will take 2 minutes. This machine has a series of sandpapers assembles in 8 drums, the drums will rotate in 60 RPM and the whole system will rotate in 7 RPM to polish each and every corner of the door precisely, even the flower designs very smoothly, which we have been doing manually and cost is very high, it takes more than 4 labors for each door. Until we have the machine start running we have to continue this manual process.
We do prime the door with zinc oxide mixed with spirit and apply on the door with a paint brush to seal the dry cell holes, so the moisture can’t penetrate in the lumber from air in the rainy season when moisture content is very high in the air. As soon as the primer dry after several hours, we brush off all the excess zinc oxide from the door with a rough paint brush and run some sand paper again to smooth up the surface before we polish.
Polishing is a very difficult task; main thing about polishing is, sanding the door properly with correct grit of abrasive, final sanding need to be done with 250-350 grit of sandpaper, clean up the dust and then start polishing. We mix gala and spirit together and let it melt in the spirit for overnight then we do start the polishing, using a soft cotton cloth. We apply the spirit, on the door gala devolved in it and keep on taking a little amount of the solution and apply on it evenly using the soft cotton cloth, certain professional way, layer after layer until we are satisfied with the shiny beauty look on it, when we are satisfied the door polish is done. Next thing is to hang the door in the frame with 3 or 4 door hinges, and a lock and couple of hinges, which I will cover in door installing. Quality door fitting is equally important, as Quality door and frame production.