The four-panel plank entry door shown here is one of many stock styles offered by this small shop in Mexico. Craftsmen use a Volkswagen motor and a three-foot saw blade to turn wood planks into doors. Because of natural variations in the wood, even stock designs end up being unique. Craftsmen stamp their names into each door.
Mesquite is harder than oak, the result of slow growth in arid climates. The denseness of the wood makes it difficult to cut and work with -- even "punishing" on saws, says the door maker. But that tight, dense grain makes for a door that's highly resistant to shrinking and swelling, even in moist climates.
The company stocks its most popular styles at a rural shipping center in Arizona, but notes that production will never be large-scale. While mesquite isn't rare, trees large enough to yield dimensional lumber are. Still, the company does offer a slight discount for bulk orders of 16 or more doors. Minimum order is two doors in stock designs. Custom orders for extra high or wide doors are also taken.
Doors are shipped lightly sanded, but unfinished. Choose a fine or slightly more expensive rustic texture. Staining is not recommended, as mesquite is a natural, deep reddish-brown with an irregular and swirling grain. Mineral streaks, beetle borings and other defects add to its unique look.
Twice as hard as oak and walnut, these doors will withstand the normal insults heaped on entry doors without denting or scratching. The manufacturer recommends finishing with either natural tung oil or with an oil-based urethane.
