12 Step Finishing Process

12 Step Finishing process

Nothing matches the look of a well-made, wrought iron iron door. The weight, the detail of the artisanal wrought iron, the stately effect it lends to any building comes together to create the most enviable door and entry space. A lot goes into creating these works of art. Not many people understand the craft, the history, and the process that is behind every iron door we create.

Here at Forever Custom Iron Doors, we have mastered and honed the process of crafting beautiful iron doors for any structure using any style, be it modern or classic for over a century. We spare no expense in making the finest iron doors the industry offers- and we do it all while keeping our prices very competitive. Most of our clients remark how much more affordable their new door was than they had expected.

But how do we do it? The answer is, we begin with the best material available, iron. Unlike wood and fiberglass doors, iron doors will never warp, can be fully corrosion proofed, and will never rot. It is the easiest and the most cost-effective material to refinish. It comes with a lifetime structural guarantee as well as a host of luxury handles, locks, hinges, and fittings- every one a work of art.

But none of this tells you how we produce our award-winning iron doors. The answer is our time-tested, proprietary finishing process. This is the secret to producing the world’s finest wrought iron doors for demanding clients all over the globe, and it’s our pleasure to explain it to you here.

Forever Iron Doors’ Finishing Process

  • Step 1: Acid Submersion: In the first step of our finishing process, we submerge the iron door in an acid etching mixture. This has two benefits; increasing the door’s adhesion properties, and removing excess debris.

  • Step 2: Zinc Coating: In step two, we coat the iron door with a special hot, zinc phosphate. This has the benefit of providing a rust-proof barrier with a handsome silver tone which can be utilized and accentuated later on if desired.

  • Step 3: Drying: Step number three takes our unfinished product into the oven for the first time. There, excess moisture is removed and the zinc phosphate becomes more secure on the surfaces of the door.

  • Step 4: Coat Welding: In step four, we weld any existing seams using steel putty. This ensures that any structural imperfections or weaknesses are eliminated, and it gives our artisans an additional opportunity to add any special flourishes that may be desired.

  • Step 5: Sanding: The steel putty beads we laid down in the previous step will be raised above the surface of the door naturally. So it is necessary to sand them down until they are flush with the overall surface of the door.

  • Step 6: Oxide Coating: Now, we spray two coats of red-oxide using an electrostatic application method. The red-oxide spray is a specialized anti-rust primer and the electrostatic spray method ensures that the coat goes on as evenly as scientifically possible.

  • Step 7: Baking to Cure: At this point, we bake the door at 365 degrees Fahrenheit for twenty minutes. This allows the coatings we’ve applied so far to cure and become even more solid and secure.

  • Step 8: Automotive Coat Base: Not willing to let any of our hard work go to waste- or to lose any of that precious iron to accident or the elements- we then spray on two coats automotive-grade powder. This becomes our base coating for the final finish which is still in process.

  • Step 9: Finish Baking: To set our achievements “in stone,” at this point we bake the door again at 365 degrees Fahrenheit, for 20 min.

  • Step 10: Hand Finish Application: Now we apply our specialized artisan faux finish, which is always done by hand. At this point, the final product is really beginning to shine, and our artists get to put some of the final brushstrokes into their latest masterpiece.

  • Step 11: Protective Coating: Not willing to risk our artisans’ valuable and painstaking handiwork- we apply another two coats of protective exterior urethane for maximum protection from the ravages of ultraviolet light.

  • Step 12: Final Curing: Finally, we bake the door again at 365 degrees Fahrenheit for the final hardening and final finish. Once the door is cooled, we give it a full inspection and prepare it for shipment to its final destination.

The Anatomy of an Iron Door

A well-made iron door is a wonderful thing to behold. Once it’s installed, it can be easy to think of it as a singular, solid thing, adding beauty and security to any structure it graces. But every door is a complex construction made of many finely interwoven parts. Here’s a quick rundown of all the components of every iron door we produce.

  • Weather Stripping: This goes all around the perimeter of the door to provide a weatherproof seal. This protects the door from corrosion and debris as well as the interior of the building it is installed in.

  • Forged Welded Hinges: These heavy-duty forged and welded hinges are works of art in their own right, sturdy enough to faithfully hold several hundred pounds and provide a secure and reliable connection to your doorway. These also come with specialized grease fittings for sealing and lubrication for long term durability and weather-tightness.

  • Adjustable Tension Rollers: Our adjustable tension rollers catch at the top and the bottom of the door. These deliver secure closing and enable the door to be opened with grace and ease.

  • High Quality 12 Gauge Steel: We choose the highest quality 12 gauge steel, which is superior to heavier gauges for their correct weight and proportions, fitment, corrosion resistance, and overall superior structural integrity.

  • Two-Inch Thick Main Body: The main body of the door is two inches of ironclad security. It is injected with urethane insulation which is exceedingly durable, light, and provides for the best weather sealing the industry provides.

  • Tempered Double Pane Glass: In the center of our decorative and functional doors exist a double tempered pane of 5/8-inch glass. This is the perfect complement to our artistic wrought iron detail work, and it can be etched with practically any image, message, title, logos, or crests the client desires.

  • Our Multi-Step Finishing Process: We’ve been over our 12-step finishing process. While this might not be considered, technically, to be a “part” of the door- it is a highly specialized process that is amenable to all of the fine components we have listed here. It brings all of these finely crafted components into one indivisible piece of artistry that is destined to beautify your building and to tell the story of the property and the people behind it.

  • The Door Sweep: Not to be forgotten is the all-important, high-quality door sweep located at the bottom, outer edge of the door. This handily sweeps moisture and debris away as the door is opened, preventing dirt, debris, and the elements from finding their ways into your building.

  • The Thermal Break: Finally, all our doors can be fitted with the optional thermal break. This highly recommended addition allows your door to provide optimal weatherproofing performance in hot, cold, wet, and dry seasons. It is also the best insurance against the mixed conditions of those in-between parts of the seasons. It consists of an interior panel and an interior panel connector. While this addition to your door will cost somewhat more, it is an excellent investment in weatherproofing you’re building which is certain to pay for itself within the first year or two of the life of your unique, personalized iron door.

Takeaways

  • At Forever Custom Iron Doors, we use a specialized 12-step process developed over centuries to create the highest quality iron doors available

  • Every iron door we create is composed of over a dozen finely-crafted components, each of which is a work of art in its own right.

  • We offer flexible financing options, enabling any property owner to become the proud owner of a fully unique, artisanal, iron door, guaranteed to last a lifetime!

Get Started with Forever Custom Iron Doors

To learn more about the time-honored art and craft of creating the world’s finest wrought-iron doors, get in touch with Forever Custom Iron Doors. View our available products, design process, and see our flexible financing options. We proudly serve the entire New Jersey and New York Metropolitan area- and beyond. Our friendly staff is standing by now, ready to answer your questions.

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    28 Harrison Avenue Building #3, Suite 301, Englishtown, NJ 07726