Inside a 290,000 Square Foot Custom Door Shop | Behind The Build with Tucker Door & Trim
Most people never see the building where their doors get made. This one is 290,000 square feet, and they are adding another 100,000. In this episode of Behind The Build, I’m at Tucker Door & Trim in Monroe, Georgia, with Jason Gert, Production Manager, who has been there 28 years, walking the full floor from the custom millwork shop to the exterior and interior door lines. We see SDL bars applied by hand, a CNC table that runs straight off an AutoCAD file, a machine that sets four door hinges at once, and why some of these jobs take a decade to learn. What’s inside: ✅ Inside the custom millwork shop: transoms, standalone radiuses, decorative glass drops, and high-end wood species like mahogany sapele ✅ Bryan Broadnax on starting at Tucker in 1999, running a Kval Commander, and working his way into custom millwork over 27 years ✅ The CNC table with two eight-foot vacuum tables, swappable head tooling, and a 90-degree tool for edge work, all driven from an AutoCAD drawing ✅ What SDL means: simulated divided lite explained, wood bars versus PVC bars, and four-lite, six-lite, and eighteen-lite configurations ✅ Albert Davis on why SDL is not a race and what patience has to do with product quality ✅ How Tucker went from Tucker, Georgia to Stone Mountain to Monroe in 2000, and what goes in the new 100,000 square feet ✅ The four exterior lines: molded steel and fiberglass singles, a custom cut-down line for Dutch doors and attic access, the Commander Line for wood singles and wood twins, and fiberglass and steel twins with sidelites and transoms ✅ Why double doors take an increased skill set and how entry personnel move from interior to exterior ✅ Interior production numbers: 250 slabs per line and up to 800 slabs a day on the high-capacity line ✅ The machine that sets four hinges at one time, plus primary and quick dump secondary screw hoppers ✅ Why satin brass is in style and decorative glass is not, and how door shops stock for the shift Featuring: Jason Gert, Production Manager, 28 years with Tucker Door & Trim Bryan Broadnax, Custom Millwork, 27 years with Tucker Door & Trim Tommy Ball, CNC Machine Operator, 13 years with Tucker Door & Trim Albert Davis, SDL Department, 19 years with Tucker Door & Trim Behind The Build takes you inside the companies that supply, build, and deliver America’s finest homes. Subscribe for more from the building materials industry. Connect with Stefanie Couch: LinkedIn: https://www.linkedin.com/in/stefaniecouch/ Website: gritblueprint.com YouTube Link: https://www.youtube.com/channel/UCvzJlThK3A5qiky1ATQEQ4A Build Authority. Gain Visibility. Drive Growth. You do great work. The right people should know it. Grit Blueprint helps building industry companies and leaders build authority, increase visibility, earn trust, and turn that trust into revenue. 📅 Book a Strategy Call Ready to become more visible, more trusted, and easier to choose? https://meetings-na2.hubspot.com/stefanie-couch 📧 Join the Newsletter Get practical strategies and tools to build your authority, grow your visibility, and strengthen your business. https://421r60.share-na2.hsforms.com/2RMwQMXe2QLyk3sl9dv2gXQ 🎥 Watch More Grit Blueprint Subscribe for honest conversations and growth strategies for the building industry. https://www.youtube.com/@stefaniecouch 🚀 About Stefanie Couch Stefanie Couch is the founder of Grit Blueprint and a third-generation building industry professional. Grit Blueprint helps manufacturers, distributors, dealers, service providers, and industry leaders build authority, grow visibility, and become unmistakable in their market. 🔗Learn more: https://gritblueprint.com Instagram: @StefanieCouchOfficial LinkedIn: Stefanie Couch
