It all starts in the forests along the Appalachian trail, extending eastward to the Atlantic coast, and southward to the gulf coast. Select yellow poplar trees are harvested by foresters who then prepare the land for replanting new growth forests insuring a sustainable, renewable resource for generations to come.
The timber is transported via truck and train to various wood mills throughout the Southeastern United States. The timber is graded, rough sized, and kiln dried to a workable product that meets our demanding specifications, ensuring a premium lumber.
The lumber is delivered to our facility where our milling department begins arduously hand grading the lumber so that we get the most out of every plank, creating as little waste as possible while never compromising the integrity of the shutter. the stock is then cut for each component; (stiles, rails, louvers and adjusting rods), in sizing and dimensioning before heading to moulding and shaping where each component receives its beautiful profile and detail.
The shutter components are then primed, sealed and sanded smooth. Rails go to be tenoned; stiles go to boring and mortising; while louvers go be cut, drilled, pinned, and stapled. All of the components converge in our assembly area where they are put together and transformed into beautiful shutters.
The shutters are once again hand sanded and primed in our abrasives and finishing area. After the second coat of primer is applied the shutters are again hand sanded before top color coating is applied. When the shutter dries it finally makes it to our staging area where each shutter receives a final inspection and hinges according to our clients’ specifications. Then the shutter is carefully packaged for shipment.