Step One

We begin with furniture grade 16 gauge hot rolled steel that has been wiped clean of processing oil and inspected for defects. Then each piece is cut to precision lengths for assembly.

Step Two

The Steel is then punched, drilled, rolled and twisted to create intricate and unique designs.

Step Three

All mitered corners and each steel joint is welded at over 1000 degrees to form a solid piece of steel for structural integrity.

Step Four

After welding grinders hand smooth each weld with three different types of abrasives until the joints are slivery smooth.

Step Five

Each door then enters a five stage wash system where they are degreased, rinsed, phosphated and sealed prior to powder coating.

Step Six

Every door is then sent to a drying oven, then to the powder coat booth where they are grounded and charged polyester powder is sprayed to just the right thickness.

Step Seven

In the oven all doors are heated to 425 degrees for a period of twenty minutes to turn the powder to a liquid and allow it to flow. At the same time the heat triggers a chemical reaction that creates the hard bonding of the particles together and to the treated metal surface.

Step Eight

Once out of the oven and cooled each door is closely inspected before moving to final assembly.

Step Nine

In final assembly the doors are outfitted with custom hardware, glass, screens and frames then re-inspected for quality assurance.

Step Ten

When doors have passed final inspection they are packaged, wrapped and loaded onto the Home Guard Fleet for delivery to our customers.

The steel thickness in of one of our doors is more than the steel that mounts the engines in some new cars

There is over 8 feet of weld in just one of our typical five picket doors.

One of our robots will travel more than 172 miles in a years time welding over 12 miles of door seams

Why do we ground the door in the powder coat booth? An electrical charge is applied to the powder as it passes through a charged field (80 kv or 80,000 volts) at the end of the powder coat gun. Because the powder particles are charged, they are attracted to a grounded object, much like metal to a magnet.

In the time a door takes to go through our five stage washer 10,000 gallons of cleaning and bonding solution will have been sprayed

The powder coating process is environmentally friendly and virtually pollution-free. Unlike liquid paint, no solvents are used, so only negligible amounts of VOCs, if any, are released into the air. Unused or over sprayed powder can be recovered, so any waste is minimal and can be disposed of easily and safely.