Project: Bryan-Chicago Illinois USA
Arched Double Door ● Asian Carving Design

1. Friday, 15-Oct-2004 >> First photo update is scheduled for Wednesday, 03-Nov-2004
2. Friday, 15-Oct-2004 >> The-Wood® Studio will provide Certificate of Authenticity for no extra cost if you choose so
3. Tuesday, 19-Oct-2004 >> Changed door orientation to "left swing" (left-hand)
4. Thursday, 11-Nov-2004 >> To insure top door quality we decided to keep the wood in kiln for additional 3 weeks and make sure that moisture level is 10%. Door panel doesn't have a support in the form of intermediate and lock rails, this is why the wood quality is so important...
5. Wednesday, 24-Nov-2004 >> The wood is still in kiln
6. Thu, 02-Dec-2004 >>

The wood was damaged during kiln process and we had to repeat entire kiln drying all over again with new teak. Below is detailed plan of action...

- 28-Nov-2004, Sunday > new teak out of the kiln
- 28-Nov-2004 - 01-Dec-2004 > air, to re-absorb the moisture
- 02-Dec-2004 - 05-Dec-2004 > second & short kiln drying
- 06-Dec-2004, Monday > assemble the door (PHOTOS)
- 07-Dec-2004 - 11-Dec-2004 > Carving (PHOTOS)
- 12-Dec-2004 > Final door assemble (PHOTOS)
- 20-Dec-2004, Monday > project finished, quality check (PHOTOS)

..we'll keep you posted and will take photos as we go...our sincere apology for the delay...

7. Mon, 06-Dec-2004 >> The wood is out of the kiln and in good quality ready for assemble. Next photo update on Saturday, 11-Dec-2004
8. Wed, 08-Dec-2004 >> Will take photos tomorrow...
9. Fri, 10-Dec-2004 >> Assembling the door. Next update on Tuesday, 14-Dec-2004
10. Mon, 13-Dec-2004 >> Next update later this week...
11. Thu, 30-Dec-2004 >> We expect to finish your door next week on Friday, 07-Jan-2005...
12. Mon, 10-Jan-2005 >> Door is finished and it's ready for shipment
13. Fri, 18-Mar-2005 >> The door is ready for shipment, finally. The quality is great. I'm sending to you by email large resolution pictures of both sides of the door..

Send email to The-Wood® Door Studio now  

Latin name "Tectona Grandis Linn". Teak or Golden Teak is the king of hardwoods and it's one of the world's most valuable timbers, recognized for its durability and stability. Teak is more durable than any other hardwood and has unparalleled rich beauty. Teak can withstand all types of weather. Ancient Burmese and Thai royalty considered teak to be a royal tree. It has been the pillar of the shipbuilding industry for centuries. The decks of the Titanic were covered in Teak, and the wood is as good today as the day she sank on 1912. Teak is also used in the Middle East oil industry as one of the very few timbers that can withstand the punishing heat of the desert and will not readily catch fire. Teak can withstand harsh chemicals, and is resistant to fungi, rot and termites. Unlike other woods, teak does not turn black when in contact with metals. It looks best when applied transparent and light colors...

KILN-DRYING

All wood in the oven for two (2) weeks to a moisture content of 10-12% followed by one (1) week of ‘resting’ to reabsorb moisture in the air to ~14%. The moisture level is measured by electronic instruments.

PANELS

Structural hardwood V-grooved minimizes the possibility of a joint separation. Permanently bonded with watertype-1 glue.

STILES & RAIL CONSTRUCTION

Mortise and tenon, glued with exterior Type-1 waterproof glue. Because wood tends to warp when it becomes damp, we make vertical rails from two separate pieces of wood, then laminating them together lengthwise, with the grain running in opposite directions. The same is done with the stiles. Then when moisture penetrates the door, the laminated pieces tend to bow in opposite directions, negating the warping effect.

MOLDING

Molding around lites and panels. Certain designs have recessed molding.

PANEL END SEALING

All panels are end sealed with under coat paint before the door is assembled to minimize shrinking and swelling.

Authentic hand carving by best Thailand’s craftsmen. No routers, no machine tools are used. Over 4,000 carving styles available for doors frames casing and lintels in many categories such as Americana, animals, architectural, Asian, business, Disney, dragons, mythology, nautical, wildlife and much more...

SANDING

Machine sanded with super fine No. 220 grit paper followed by detailed hand sanding. No machine or cross grain sand marks. Ready for finish.

1. 12-Step PermaLane II®
2. Penetrating wiping stain sets the color
3. Three Separate coats of alkyd moisture seal with fine sanding between coats
4. Two coats of imported from Germany ‘Bayer Brand’ catalyzed Poly-Urethane with ultraviolet absorbers. Light sanding between coats
5. Stain brightener applied
6. Detailed hand rubbed to smooth satin finish

PACKING

Each door is individually poly bagged and boxed with 300# psi doubled wall cardboard and placed in wooden crate.

FUMIGATION

Every door together with wood crating, pallet and all Non-Manufactured Wood Packing Material (NMWP) to be fumigated with Methyl Bromide [CH3Br] and are free from wood termites. Formal Certificate of Fumigation is provided according to wood import regulations of European Union, United States, Canada, New Zealand and Australia.

WARRANTY

The-Wood Studio 2-Years Limited Warranty

CERTIFICATE OF AUTHENTICITY

We issue a Lifetime Certificate of Authenticity. The-Wood Studio certifies that every door we design and make is by order only. This is an original and authentic product. It is genuine and the only one made by The-Wood Studio. It is not a replica, a rebuild or repair; it has been newly built by skilled artisan. No two doors are identical, thus making each one of a kind. Only authentic hand carving is performed, no routers or machine tools of any type are used.

1. Insurance 100% from damage or loss by US company based in Chicago
2. Chicago based shipping company in charge
3. Sea-freight from Bangkok Thailand to Chicago, Illinois USA
4. Transit Time: 35 days

Updated 01-Aug-2007