Custom Teak Doors with Carving
The-Wood® Studio
Chiang Mai  Thailand
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Project: Mike-Butte Montana USA
Double Exterior Wood Door ● Custom Design

  Home | Custom > Design > Projects > Mike-Butte  
  q Specifications q Panels q Finishing
  q Delivery Time q Stiles & Rail Construction q Packing
  q Project Updates q Molding q Fumigation
  q Communication q Panel End Sealing q Warranty
q Teak (Tectona Grandis Linn) q Carving q Certificate of Authenticity
q Kiln-Drying q Sanding q Insurance & Shipping

THE PROJECT: Double Exterior Wood Door | Custom Carving

Front Carving

Back Carving

Top View










  Description:   Double Exterior Wood Door  
  Carving Number:   Custom Carving / American Wild Sheep  
  Door Type:   Double Rectangular  
  Wood Type:   Teak grade “A” (Tectona Grandis Linn)  
  Carving Location:   Both sides of the door  
  Slab Dimensions:   36" X 80"  
  Door Units:   one (1)  
  Door Thickness:   1 3/4 inch (45 mm) US Standard  
  Finish:   Pre-Finished  
  Frame:   no frame  
  Orientation:   Right Swing  

  Door Production/Carving Time:   12 weeks  
  Shipping Size:   36" X 80" X 1-3/4" (X2)  
  Date Project Started:   06-Oct-2004  
  Expected Finish Date:   06-Jan-2005  
  Shipping Bangkok to Salt Lake City, Utah:   35 days  


















Front View/01

Front View/02

Front View/03

Back View/01

Back View/02

Back View/03



  1. Tuesday, 05-Oct-2004 >> First photo update is scheduled for Wednesday, 03-Nov-2004
  2. Tuesday, 05-Oct-2004 >> The-Wood® Studio will provide Certificate of Authenticity for no extra cost if you choose so..
  3. 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 is 1 3/4 inch thick and this is why the wood quality is so important...
  4. Wednesday, 24-Nov-2004 >> The wood is still in kiln
  5. 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...

  6. 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
  7. Wed, 08-Dec-2004 >> Will take photos tomorrow...
  8. Fri, 10-Dec-2004 >> Assembling the door. Next update on Tuesday, 14-Dec-2004
  9. Mon, 13-Dec-2004 >> Next update later this week...
  10. Thu, 30-Dec-2004 >> We expect to finish your door next week on Friday, 07-Jan-2005...
  11. Mon, 10-Jan-2005 >> The door is finished. We decided to install t-astragal to give you extra isolation and better weather will take only few more days to complete...
  12. Sat, 15-Jan-2005 >> The door is finished and ready for shipment...

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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...




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.




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




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 around lites and panels. Certain designs have recessed molding.




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...




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


Three Separate coats of alkyd moisture seal with fine sanding between coats



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




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.




The-Wood Studio 2-Years Limited Warranty




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 California
  2. California based shipping company in charge
  3. Sea-freight from Bangkok Thailand to Salt Lake City, Utah USA
  4. Transit Time: 35 days

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Updated 15-Mar-2005