Sun Mountain Blog

Custom Size Doors (Thickness, Width, and Height)

Did you know that Sun Mountain can manufacture custom size doors—custom thicknesses, widths, and heights? We commonly produce custom sizes to match existing door openings in upscale remodeling projects, or to meet a specific design or application in a new luxury home.


While the majority of the doors we manufacture are 1-3/4” thick, we commonly make 2-1/4”, 2-1/2”, or even 3” thick doors. Generally, the stiles and rails (or structural frame) of these doors are “engineered” to resist warping (with a Laminated Veneer Lumber, or LVL, core sandwiched between 1/8” thick veneers and solid wood edge caps). Solid wood components of these thick doors (such as the bottom kick rails of exterior doors, stiles on arched-top doors, and all panels) are made with two layers of wood, face glued together to create the required thickness. We alternate the grain of the two wood layers, creating a natural resistance to bowing or cupping.


Two Piece Panel

Thick doors can be very heavy—an important element of the substantial “feel” of the door. Sun Mountain calculates the proper hinge size, hinge count, and engineers the door jamb to safely and perfectly operate thick doors. For example, while a 1-3/4” thick door may have 3 hinges 4” in size, a 2-1/2” thick 8′ height door may have 5 ball-bearing hinges 4.5” in size to support the additional weight. On thick doors, hinges are also screwed through the door frame and into the stud wall, to provide additional support for the heavy door.


Sun Mountain manufactures standard width door sizes to meet most applications. These widths include 1/6, 2/0, 2/4, 2/6, 2/8, and 3/0. But we can also manufacture custom widths. We can add (or take away) as small as ¼” to/from standard width sizes, to fit existing openings or special needs. Sun Mountain can also manufacture wide width doors—4’, 5’ or even 6’ wide individual doors. For example, the 6’ wide barn door below is displayed in our company showroom at the San Francisco Design Center.

Rustic Barn Door


Common door heights manufactured by Sun Mountain include 6/8 (the standard height for most passage doors), 7/0, 7/6, and 8/0. But we can also manufacture custom heights. We can add (or take away) as small as ¼” to/from standard height sizes, to fit existing openings or special needs. We can also manufacture small height doors, such as the 3/0 height door shown below, or very tall doors. For example, we regularly receive demand for 9’ high doors. The tallest door Sun Mountain has manufactured is 20’ in height.

31096, Small Door Under Glass Stairs

Contact us at 888.786.6861 or go to to request a free quote.