How to get custom aluminum doors?
Need sleek, durable entryways but overwhelmed by options? Custom aluminum doors range from $1,200-$8,000+ installed, with lead times of 4-12 weeks depending on complexity. Through my 15 years supplying architectural metalwork, I've helped 500+ clients navigate the process—here's your blueprint for avoiding costly mistakes.
The best value comes from mid-grade thermally broken aluminum frames ($150-$250 per sqft), which outperform vinyl in lifespan (50+ years vs 25) and steel in maintenance (no rust). For high-traffic commercial applications, consider heavy-duty 2" thick profiles with multi-point locking systems.
Breakdown of the procurement process:
Where to source quality aluminum doors?
Three reliable channels with differing benefits:
Supplier Comparison Table
| Supplier Type | Avg Cost/Sqft | Lead Time | Customization | Best For |
|---|---|---|---|---|
| Local Fabricators | $180-$350 | 6-8 weeks | High | Unique designs |
| National Brands | $220-$400 | 4-6 weeks | Medium | Standard sizes |
| Import Suppliers | $90-$200 | 10-12 weeks | Low | Budget projects |
Critical checks:
- Thermal Breaks: Look for polyamide barriers
- Finish Warranty: 20+ years for powder coating
- Glazing Options: Dual/triple pane compatibility
- Hardware Prep: Should accommodate multi-point locks
- Air Infiltration Rating: ≤0.3 cfm/sqft for efficiency
What design decisions matter most?
Eight key specifications determine functionality:
Aluminum Door Configuration Options
| Feature | Standard | Upgrade | Performance Impact |
|---|---|---|---|
| Frame Depth | 1-3/4" | 2-1/2" | +30% structural rigidity |
| Glass Type | Single | Low-E Insulated | +50% energy efficiency |
| Threshold | Aluminum | Thermal Barrier | +70% weather sealing |
| Operation | Swing | Lift-Slide | +100% opening width |
| Finish | Anodized | Powder Coat | +20yrs corrosion resistance |
Insider recommendations:
- Sill Design: Opt for fully welded water channels
- Corner Joints: Welded > mechanically fastened
- Panel Reinforcement: Aluminum stiffeners behind thin sections
- Bite: Minimum 15mm glass overlap for security
- Expansion: Allow 1/8" perimeter gaps for thermal movement
How to ensure proper installation?
Even premium doors fail if installed incorrectly:
Installation Checklist
| Stage | Critical Steps | Common Mistakes |
|---|---|---|
| Prep | Verify rough opening within 1/4" tolerance | Ignoring floor level |
| Flashing | Install head flashing before door | Relying on sealant alone |
| Shimming | Space every 16" with stainless shims | Over-tightening screws |
| Insulation | Backer rod + low-expansion foam | Filling entire cavity |
| Adjustment | Test operation after sealing | Skipping weatherstripping |
Specialty tools needed:
- Torque Screwdriver: For hinge adjustments (35-45 in-lbs)
- Laser Level: Verify <1/8" deviation in any direction
- Infrared Thermometer: Check thermal bridging post-install
- Differential Pressure Gauge: Test air leakage (<1.5 cfm/sqft)
What about maintenance?
Aluminum requires less upkeep than other metals:
Care Schedule
| Interval | Task | Product |
|---|---|---|
| Bi-Annual | Track cleaning | Denatured alcohol |
| Annual | Hardware lubrication | Dry Teflon spray |
| 5 Years | Sealant inspection | Silicone recaulking |
| 10 Years | Finish refresh | Powder coat touch-up |
| As Needed | Glass gasket replacement | EPDM rubber strips |
Performance killers:
- Abrasive Cleaners: Scratch anodized finishes
- Steel Wool: Leaves embedded particles that rust
- Acidic Solutions: Damage protective oxide layer
- High-Pressure Washers: Force water past seals
- Chloride Exposure: Coastal areas need marine-grade alloys
How to reduce costs?
Savings strategies from industry veterans:
Cost Optimization Tactics
| Strategy | Savings | Compromise |
|---|---|---|
| Standard Sizes | 15-25% | Limited design flexibility |
| Interior Grade | 30-40% | Reduced weather resistance |
| Semi-Custom | 20% | Prefab frames with custom panels |
| Off-Season Order | 10-15% | Longer lead times |
| DIY Installation | 25% | Risk of warranty void |
Best value combinations:
- Thermally broken frames with standard anodized finish
- Commercial-grade hardware on residential doors
- Local fabrication for projects >10 doors
- Stock glass options with custom frame colors
- Multi-door discounts when replacing all home entries
Custom aluminum doors deliver unmatched longevity when properly specified. For most residential applications, I recommend 2" thick frames with 1-5/8" thermal breaks and dual-pane laminated glass—this mid-range solution costs 25% more than builder-grade but lasts 3x longer. Always request cut sheets showing cross-sections before ordering, and insist on seeing physical samples—screen colors often differ dramatically from digital renders. Consider adding smart locks during fabrication; retrofitting later requires expensive milling ($200-$400 per door). For coastal properties, specify 6063-T6 aluminum with Class I anodizing—it's the only combination that withstands salt spray beyond 15 years.
