Design Carved Wood Doors
WoodLtdŽ Studio
Chiang Mai  Thailand
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Single Arched Exterior Door with Roman Carving Design
Dave-North Carolina USA

 
 
 
  Home | WoodLtd Studio | Door Catalog | Current Projects > Dave-NC  
     
  TABLE OF CONTENTS  
 
  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: Single Custom Exterior Door

The Door

Casing Curve

Door Casing

Door Color

Door Design

Door Details

Door Head Carving

Head Details

Head Carving Style

Locksets

Door Certificate

 

 

SPECIFICATIONS

     
  Description:   Exterior Single Arched Door  
  Reference Number:   ANTDR102 / Roman Door  
  Wood Type:   Genuine Solid Teak grade A  
  Carving Location:   Both Sides of the Door  
  Slab Size:   48" X 108" inches  
  Door Thickness:   3"  
  Rough Opening:   will build to fit  
  Wall Thickness:   6 inches  
  Frame:   Pre-Hung  
  Frame Depth:   6.0"  
  Door Units:   one (1) arched door  
  Finish:   Finished with Color  
  Frame Material:   Rosewood  
  Head Carving:   Exterior Side Only  
  Hinges:   Solid Brass  
  Casing Design:   Carved / same as t-astragal / see photo above  
  Casing Exterior:   5" wide X 5" deep. Carved, varying depth, same as the photo  
  Casing Interior:   4" wide X 1.5" deep / matching design and style as front casing  
  Direction:   In-Swing  
  Orientation:   Right Hand  
  Hardware/Bore:   provided by client / door-set size 22-1/2" tall X 3-1/2" wide  
  Door Color:   see photo above  
 

DELIVERY TIME      
  Door Production/Carving Time:   3 months  
  Casing Exterior:   5" X 5" X 108" = 2 pcs  
  Casing Curve Exterior:   20" X 4" X 60" = 1 pc  
  Head Carving:   12" X 4" X 48" = 1 pc  
  Casing Interior:   5" X 1-1/2" X 108" = 2 pcs  
  Casing Curve Interior:   20" X 1-1/2" X 60" = 1pc  
  Date Project Started:   21-Jun-2005  
  Expected Finish Date:   21-Sep-2005  
  Shipping Bangkok to Charlotte, NC:   35 days  
 
 
  PROJECT UPDATES  
 

Artist's Vision

19-Aug-2005/1

19-Aug-2005/2

19-Aug-2005/3

15-Sep-2005/1

15-Sep-2005/2

15-Sep-2005/3

15-Sep-2005/4

15-Sep-2005/5

15-Sep-2005/6

15-Sep-2005/7

15-Sep-2005/8

15-Sep-2005/9

The Carver

01-Oct-2005/2

01-Oct-2005/3

01-Oct-2005/4

01-Oct-2005/5

01-Oct-2005/6

01-Oct-2005/7

08-Oct-2005/1

08-Oct-2005/2

08-Oct-2005/3

08-Oct-2005/4

08-Oct-2005/5

30-Oct-2005/01

30-Oct-2005/02

30-Oct-2005/03

30-Oct-2005/04

30-Oct-2005/05

30-Oct-2005/06

30-Oct-2005/07

30-Oct-2005/08

30-Oct-2005/09

30-Oct-2005/10

11-Dec-2005/1

11-Dec-2005/2

11-Dec-2005/3

11-Dec-2005/4

17-Dec-2005/1

17-Dec-2005/2

17-Dec-2005/3

17-Dec-2005/4

05-Jan-2006/1

05-Jan-2006/2

16-Jan-2006/1

16-Jan-2006/2

16-Jan-2006/3

16-Jan-2006/4

16-Jan-2006/5

18-Feb-2006/01

18-Feb-2006/02

18-Feb-2006/03

18-Feb-2006/04

18-Feb-2006/05

18-Feb-2006/06

18-Feb-2006/07

18-Feb-2006/08

18-Feb-2006/09

18-Feb-2006/10

18-Feb-2006/11

18-Feb-2006/12

18-Feb-2006/13

30-Mar-2006

22-Apr-2006/01

22-Apr-2006/02

22-Apr-2006/03

22-Apr-2006/04

22-Apr-2006/05

22-Apr-2006/06

22-Apr-2006/07

22-Apr-2006/08

22-Apr-2006/09

22-Apr-2006/10

26-Apr-2006

 

  COMMUNICATION
  1. Monday, 20-Jun-2005 >> First photo update is scheduled for Friday, 22-Jul-2005
  2. Monday, 20-Jun-2005 >> WoodLtd Studio will provide a Certificate of Authenticity for no extra cost if requested...
  3. Sunday, 10-Jul-2005 >> Above is a door drawing <Artist's Vision> the way our artist see it...Please kindly email me your comments. Once you OK the drawing we'll cut the wood.
  4. Sunday, 10-Jul-2005 [Reply from the Client "Dave-NC"] >> BREATHTAKING and EXQUISITE are the only words that can remotely describe the rendition of the door your artist created. Thank you so much for capturing the essence of what we only hoped to achieve. We cannot think of a more fitting way to welcome visitors to our new home with this fabulous and awesome piece of artwork!! Again thank you so much. We eagerly await to enjoy this masterpiece in person!!

  5. Saturday, 23-Jul-2005 >> The wood has been cut and was placed in kiln for drying. We'll dry the wood for about three (3) weeks total. The wood drying should be finished around 06-August-2005...

  6. Friday, 05-Aug-2005 >> The wood will remain in kiln until 20-Aug-2005, we're checking the moisture content by electronic devices every 7 days. The drying process takes a little bit longer because of the rainy season in Thailand...

  7. Friday, 19-Aug-2005 >> The wood was removed from kiln 2 days ago. We assemble the door now, this should take 10-14 days. Next update on Thursday, 01-Sep-2005...

  8. Thu, 15-Sep-2005 >> We started carving the door on 10-Sep-2005. The carving will last for 3-4 weeks. Next update on 01-Oct-2005

  9. Sat, 01-Oct-2005 >> Carving of the both sides of the door is completed. We're working on casing and lintel now. In the next few days we'll build a frame. Will apply color between 07 and 21-October-2005. The door should be ready for shipment by the end of the month.

  10. Fri, 14-Oct-2005 >> We'll add the carving to the lower part of the door, please help us with carving design! I am waiting for your reply by email... Some drawings are attached to my email <lower.carving.zip>

  11. Sun, 30-Oct-2005 >> The carving on the lower part of the door has been adjusted, see two photos above 30-Oct-2005/01 (before) and 30-Oct-2005/02 (now) Please email me your OK and we'll continue... BTW: I hope that you like the piano music :-)

  12. Tue, 15-Nov-2005 >> No pictures today, sorry. We're working on door surround and casing now. We also apply the color and finish on the door. Expect to finish the project by 30-Nov-2005..

  13. Thu, 01-dec-2005 >> We are running late. It is a rice harvest season in northern Thailand now and people do farming. We are working on door surround and apply the color now. We expect to ship the door on 15-Dec-2005...

  14. Sun, 11-Dec-2005 >> Sanding is nearly finished, next week we'll apply the color and door should be ready for shipping...

  15. Sat, 17-Dec-2005 >> We needed six (6) Thai man to set the door in upright position today. The door is 48" wide, 108" high and 3" thick. The four pictures above are showing both sides of the door.

  16. Thu, 05-Jan-2006 >> We apply color and work on finishing now. Expect to have door ready for shipping by 20-Jan-2006

  17. Mon, 16-Jan-2006 >> We continue working on stain and finishing. We're less than 10 days to shipping day...

  18. Sat, 18-Feb-2006 >> The door is ready for shipping...

  19. Wed, 08-Mar-2006 >> We're working on the frame now. The door will be ready for shipping by 20-Mar-2006...

  20. Tue, 21-Mar-2006 >> The door finish day has been moved till 31-Mar-2006...

  21. Thu, 30-Mar-2006 >> Making a new door frame now...

  22. Sat, 22-Apr-2006 >> The shipping is scheduled for Thursday, 27-Apr-2006...

 

Send email to The-Wood Studio now  Send email!

 
 
  TEAK

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.

 

  CARVING

Authentic hand carving by best Thailands 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...

 

FINISHING (MARITIME)
  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

 

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.

 

 

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.

 

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

             
 

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Updated 20-Jun-2005