How to select the best wood for an exterior entry door

The best wood for an exterior door is going to hinge on a lot of different factors, no pun intended. 🙂 

The first thing to consider is whether your door will be painted, stained, or just sealed. Solid wood doors are not as common as they used to be but they add an element of timeless beauty to your home that engineered veneer can’t compete with. A well-built solid wood door can withstand harsh weather conditions and seasonal changes. While there may not be such a thing as the ideal wood, since much of the decision-making comes down to the style, color, and look you are after. The main difference between an exterior door and an interior door is the method of construction, overall thickness, and that exterior doors are solid, while most interior doors are hollow on the inside.  

It would make little to no sense to have an exterior door that is made from Walnut only to paint it,  you would be much better off choosing a wood like Hard Maple, Poplar or Straight grain doug fir.

In my area, as in most of the United States, hardwood lumber prices are generally similar, given this fact some hardwoods are considered more of paint-grade wood and some are considered stain-grade, stain-grade being the wood with the more naturally pleasing wood grain and color. Quality hardwoods are a must before building any custom wooden doors, you should make sure that the hardwood supplier you use, has adequately dried lumber. Most hardwood dealers will use kiln-dried lumber but you can always have your craftsman check the moisture content with a moisture meter. Having too high moisture content in solid timber doors makes them susceptible to warping over time. 

If you want a wood door that will be stained or just sealed, highlighting the beauty of the wood here are some common hardwoods you will find in the United States.

Walnut, quarter-sawn oak, sapele, chestnut. While mahogany is a good choice, its availability takes it off the list here.  These species range from 6-12 dollars a board ft in my area of California. It is possible to get these woods cheaper but I don’t think you will find them for much less than about 5-6 dollars a board ft. Red oak was also once a popular wood for doors and furniture but, due to the fact I rarely see any doors from red oak now I’m going to leave it off the list. Maybe in the future, it will become a popular option as the building material of choice, but for now, it seems to be less in demand. 

The best stain-grade hardwoods for an exterior door 

1. Sapele 

f you showed two people a new door, one mahogany door and one sapele door, very few would be able to tell the difference, that’s why sapele is known as the more affordable and easier to find mahogany. Sapele is also a great choice for a hardwood, it has a Janka hardness of 1,360 lbf which is harder than walnut and is generally less expensive and easy to work with.

Using sapele wood for exterior wood doors offers several benefits, making it a popular choice for both aesthetic and functional reasons:

• Beautiful Appearance: Sapele wood is prized for its striking appearance, characterized by a rich reddish-brown color and a lustrous grain pattern. Its natural beauty adds elegance and warmth to any front entrance, enhancing the home’s curb appeal.

• Durability: Sapele is a highly durable hardwood with excellent resistance to rot, decay, and insect infestation. It possesses similar durability characteristics to mahogany, making it suitable for exterior applications where the door is exposed to the elements.

• Stability: Sapele wood is known for its stability, meaning it is less prone to warping, twisting, or shrinking due to changes in humidity or temperature. This stability ensures that sapele front doors maintain their structural integrity over time, minimizing the need for repairs or adjustments.

• Workability: Sapele is relatively easy to work with, allowing for intricate detailing, carving, and customization in front door design. It can be machined, shaped, and finished to achieve various styles and profiles, catering to different architectural preferences.

• Weather Resistance: When properly sealed and finished, sapele wood exhibits excellent resistance to moisture, UV exposure, and weathering. This makes it well-suited for exterior doors that are constantly exposed to rain, sunlight, and other environmental factors.

• Less Maintenance: Sapele front doors require minimal maintenance to keep them looking their best. Periodic cleaning and resealing are typically all that’s needed to preserve the wood’s natural beauty and protect it from the elements.

• Cost-Effectiveness: Compared to some other hardwoods commonly used for front doors, such as mahogany or teak, sapele wood often comes at a more affordable price point while still offering similar durability and aesthetic qualities. This makes it a cost-effective option for homeowners seeking high-quality front doors on a budget.

• Sustainability: Sapele is harvested from responsibly managed forests, and its availability is relatively abundant. Choosing sapele for a front door supports sustainable forestry practices and reduces the environmental impact associated with door construction.

Sapele wood has a winning combination of beauty, durability, stability, and affordability, making it an excellent choice for front doors that make a lasting impression while withstanding the rigors of outdoor exposure.

2. Walnut: 

You won’t find a solid wood door made from walnut at your local Home Depot, typically walnut is used by custom door builders for clients that want the best. Using walnut wood for exterior doors offers several benefits that contribute to both the aesthetic appeal and functional longevity of the door. Here are some key advantages:

• Natural Beauty: Walnut is renowned for its rich, deep color and attractive grain patterns. Its warm tones can add elegance and sophistication to the exterior of a home, enhancing its curb appeal.

• Durability: Despite being a relatively softer hardwood than oak or mahogany, walnut is still highly durable. When properly treated and finished, walnut wood can withstand exposure to the elements, including moisture, sunlight, and temperature fluctuations.

• Stability: Walnut wood is known for its stability, meaning it is less prone to warping, twisting, or shrinking when exposed to changes in humidity or temperature. This stability ensures that walnut exterior doors maintain their structural integrity over time.

• Workability: Walnut is moderately easy to work with, making it a preferred choice for intricate designs or customizations in exterior door construction. Carvings, moldings, and other decorative elements can be easily incorporated into walnut doors.

• Weather Resistance: While walnut may not be as naturally weather-resistant as some other hardwoods, such as teak or cedar, it can still withstand outdoor exposure well when properly sealed and maintained. Regular sealing and finishing can help protect the wood from moisture and decay.

• Aging Gracefully: Walnut develops a beautiful patina as it ages, further enhancing its visual appeal over time. This natural aging process adds character and charm to walnut exterior doors, making them even more attractive as they mature.

• Sustainability: Walnut trees are generally harvested from responsibly managed forests, making walnut wood a sustainable choice for exterior door construction. By choosing walnut doors, homeowners can support eco-friendly forestry practices and minimize their environmental impact.

• Unique Character: Each piece of walnut wood is unique, with variations in grain patterns and coloration. This inherent uniqueness adds a touch of individuality to walnut exterior doors, ensuring that no two doors are exactly alike.

Overall, walnut wood is the best type of wood if you like just a clear coat finish, its natural dark rich color is rarely if ever stained or modified, it offers a perfect blend of aesthetic beauty, durability, and workability, making it an excellent choice for crafting high-quality exterior doors that enhance the appearance and value of any home.

The factor of cost will always be a consideration of any project, walnut, and quarter-sawn oak will probably be the most expensive no matter what area you are in. Quarter-sawn oak will be more stable than regular white oak, but the lumber you buy can sometimes come in much smaller pieces and will require many gue-ups to get the desired dimensions of all the components of your door. I have never made a door out of quarter-sawn oak but I can imagine that a project like that could be a major undertaking in terms of both cost and time. Make sure you are very set on quarter-sawn oak if you choose this as your material of choice

3. Chestnut

Chestnut wood, particularly American chestnut, historically held a reputation for its durability and suitability for exterior applications. However, due to the devastation caused by the chestnut blight in the early 20th century, American chestnut trees have become rare, and chestnut wood is not commonly available for commercial use today.

That said, other varieties of chestnut, such as European chestnut, may still be used for exterior applications, including doors, albeit with some considerations:

Benefits:

• Durability: Chestnut wood is naturally resistant to decay and rot, making it suitable for outdoor use. It can withstand exposure to moisture, insects, and environmental elements, making it a durable choice for exterior doors.

• Stability: Chestnut wood tends to be stable, meaning it is less prone to warping, twisting, or shrinking when exposed to changes in humidity or temperature. This stability helps maintain the structural integrity of exterior doors over time.

• Attractive Appearance: Chestnut wood often features a warm, rich color with prominent grain patterns, adding natural beauty and character to exterior doors. It can be finished to enhance its appearance and protect it from the elements.

Considerations:

• Availability: American chestnut wood is scarce due to the chestnut blight, while European chestnut may be more readily available but still less common than other hardwoods. Limited availability may affect the accessibility and cost of chestnut exterior doors.

• Cost: Chestnut wood, especially if sourced from sustainable or reclaimed sources, may be more expensive compared to other hardwoods due to its scarcity and desirable characteristics.

• Maintenance: While chestnut wood is naturally durable, exterior doors made from chestnut still require regular maintenance, including sealing or finishing to protect against moisture, UV exposure, and other environmental factors.

• Sustainability: When considering chestnut wood for exterior doors, it’s essential to verify the source and ensure it comes from responsibly managed forests or reclaimed sources to support sustainable practices.

In conclusion, while chestnut wood offers durability, stability, and attractive aesthetics, its availability and cost may be limiting factors for its use in exterior door construction. Homeowners interested in chestnut doors should weigh these considerations and explore alternatives or specialty suppliers to find the best option for their needs.

4.Quarter Sawn White Oak

Using quarter-sawn oak for a front door can offer various benefits and downsides, each of which should be carefully considered before making a decision:

Benefits:

• Enhanced Stability: Quarter-sawn oak is known for its exceptional stability compared to other cuts of wood. The unique grain orientation achieved through quarter sawing minimizes the wood’s tendency to warp, twist, or cup, making it an ideal choice for exterior doors that are exposed to varying weather conditions.

• Distinctive Grain Patterns: Quarter sawing reveals beautiful ray flecks and medullary rays in the wood, creating a unique and visually appealing grain pattern. This distinctive appearance adds character and elegance to the front door, enhancing the overall aesthetic appeal of the home’s exterior.

• Durability: Oak is a hardwood renowned for its strength and durability. When quarter sawn, oak becomes even more resistant to wear, making it highly suitable for exterior applications where the door may be subjected to heavy use and exposure to the elements.

• Resistance to Moisture: Oak has a natural resistance to moisture, which is further enhanced by quarter sawing. This makes quarter-sawn oak front doors less susceptible to swelling, rotting, and decay caused by moisture infiltration, ensuring long-term durability and performance.

• Ease of Finishing: Quarter-sawn oak takes stains and finishes exceptionally well, allowing homeowners to achieve their desired look with ease. Whether opting for a natural wood finish to highlight the unique grain patterns or a painted finish to complement the home’s exterior color scheme, quarter-sawn oak provides versatility in design.

Downsides:

• Cost: Quarter-sawn oak is typically more expensive than other types of wood due to the specialized cutting process required to produce quarter-sawn lumber. The higher cost of materials may be a consideration for homeowners working within a limited budget.

• Availability: While oak is a widely available hardwood, quarter-sawn oak may be less readily available compared to plain-sawn or rift-sawn oak. Limited availability could potentially impact project timelines or require sourcing from specific suppliers.

• Maintenance: While oak is durable, it still requires regular maintenance to preserve its appearance and structural integrity. Periodic sealing or refinishing may be necessary to protect the wood from environmental factors and maintain its aesthetic appeal over time.

• Weight: Oak is a dense and heavy wood, which can make quarter-sawn oak doors heavier than those made from other materials. Proper installation and hardware selection are essential to ensure smooth operation and longevity of the door.

• Sensitivity to UV Exposure: Like many wood species, oak can be sensitive to prolonged exposure to ultraviolet (UV) radiation, which may cause fading or discoloration over time. Applying a UV-protective finish can help mitigate this issue.

In conclusion, while quarter-sawn oak front doors offer numerous advantages such as stability, durability, and distinctive aesthetics, they also come with considerations regarding cost, availability, maintenance, weight, and sensitivity to UV exposure. Homeowners should weigh these factors carefully to determine whether quarter-sawn oak is the right choice for their front door based on their preferences, budget, and specific project requirements.

Closing Thoughts:

Wood movement is a constant topic in the woodworking community and some opinions range from that it is a complete myth to that everything you do, you must account for wood movement to the extreme. 

However, like many topics, the topic of wood movement is nuanced. For instance, you should take your local climate into account as wood movement in a hot and dry State such as Arizona will probably be much less than if you lived somewhere like the Pacific Northwest.

For example, if we take a 6-inch wide piece of Kiln dried walnut in Santa Barbara California it is estimated to have about a maximum movement of 0.04 (≈ 5/128) inch(es) over the course of a year.

You may say that’s a negligible amount but if you have a wide panel that’s 27in wide you can expect around a ¼ inch of wood movement over the course of a season. That’s not a negligible amount.  

One way to minimize the effects of wood movement and/or warping or cupping on your door is with the type of construction you use. 

Using dominos, floating tenons, or through tenons for the joinery will ensure that your door stands the test of time.  Custom exterior doors are a lot of work to make and because of that they can have a heft price tag but they remain the best choice for those who love a traditional and warm look. 

I have seen and repaired a door that was built cutting corners and not factoring in the cupping movement of a wide inset panel. The result was the panel’s cupping action overpowered the wood trim that held the panel in place and the whole panel cupped and popped out of the door once some heavy weather started. 

This particular door had many things that I would not recommend. 

1. It was made from Poplar but stained and coated with a cheap polyurethane. 

2. The floating panels were not rabbetted into the door but only held in with thin trim and brad nails (this is what came apart) 

3. The finish was already flaking off after only one year of being exposed to the elements. 

4. Poplar is most typically a paint grade hardwood not a stain grade hardwood.

Some typical methods that are used to minimize the effects of wood movement are making components of the door engineered. That is gluing up many pieces of wood sometimes in alternate fashion to create a solid piece of wood that resists movement, much like plywood. 

Make sure that your rails and stiles are joined with traditional mortise tenon joints, floating tenons or sufficiently big dominos to withstand seasonal expansion and contraction. 

I replaced an antique set of french doors that were made from straight grained doug fir, they had been painted and were probably about 100 years old, judging by the hardware and the hinges. The doors themselves were still very much intact and had not warped or twisted, aside from the massive amount of paint build up, the construction of the doors was still quite solid. The rails and stiles had traditional through tenons and the panels were rabbeted in. The construction method of these doors played a large role in their durability and longevity, probably just as much if not more than the type of wood.