He entered Thailand on an expired passport, if it is "illegal", it is allowed!
No Custody dispute now, I have had Full Parental Control of both my kids for many years (and their Mother lives in Aus.)
Anyway no worries now, Passport Office at Central Phuket, the staff there are super nice and helpful, processed his passport yesterday, they think it should arrive this Friday which gives us 4-5 clear working days before the flight.