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Build Japanese-style dividers to allow for natural light and privacy using hardwood with acrylic panels.
By Handyman Magazine
Traditional oriental screens are easily damaged as the panels are made of rice paper but using frosted acrylic with maple frames modernises this project.
It costs about $700 to make a pair of doors mounted with a 2500mm sliding door kit that has a top guide rail, four wheel assemblies and a track along the floor.
TIP: Buy the tracks for about $80 from a door specialist or hardware store.
Installing the panels
Use 12 x 9mm splayed beading cut with 45ยบ mitres to secure the acrylic panels to the maple frame bars, marking and securing it as you go.
Cut the panels from a sheet of 3mm acrylic, using a jigsaw on low speed with a fine blade and the pendulum action switched off or have it cut by the supplier.
TIP: The beading is set back from the edge with a 2.5mm gap called a quirk.
For accurate assembly
Before securing, dry-fit the frame to check for square and adjust as needed, sanding the bars or using a chisel to shave the rail housings.
To secure stiles to the rails use 50mm x 8g timber screws, recessing the heads and plugging with 10mm dowels.
Assemble the bars and pelmet with 25 x 1.25mm panel pins.
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Essential tools and equipment step 1. Cut joints accurately
This project relies on precise joinery that requires careful measurement and accurate cutting.
The joints should be tight enough for the doors to be completely assembled dry before securing with adhesive and fasteners.
Tools for the job
For precise routing use a Dremel rotary tool with a router attachment.
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Traditional oriental screens are easily damaged as the panels are made of rice paper but using frosted acrylic with maple frames modernises this project.
It costs about $700 to make a pair of doors mounted with a 2500mm sliding door kit that has a top guide rail, four wheel assemblies and a track along the floor.
TIP: Buy the tracks for about $80 from a door specialist or hardware store.
Keeping it together
Use sash clamps or smaller pairs for assembly, applying equal pressure.
Build the sliding doors step 1. Mortise the wheel pockets
On the base rails, measure and mark 51 x 10mm wheel pockets centred 75mm from the ends, drilling a series of 2mm relief holes 16mm deep then chiselling out the waste.
TIP: Wrap masking tape around the drill bit as a depth indicator.
Step 2. Make the guide grooves
On the top rails, rout a centred 5mm groove 9mm deep for the pelmet guide then repeat in the top of the stiles, ensuring the grooves align.
TIP: Adjust the size of the pockets and grooves to suit if using a different-size track and wheel kit.
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Traditional oriental screens are easily damaged as the panels are made of rice paper but using frosted acrylic with maple frames modernises this project.
It costs about $700 to make a pair of doors mounted with a 2500mm sliding door kit that has a top guide rail, four wheel assemblies and a track along the floor.
TIP: Buy the tracks for about $80 from a door specialist or hardware store.
Step 3. Chisel out the housings
On the rails mark 12 x 6mm housings 271mm from the ends.
At the ends of the stiles mark 65 x 6mm housings and 12 x 6mm housings for the horizontal bars.
Clamp the rails then stiles together to cut the housings and chisel out the waste.
Step 4. Cut the half-lap joints
Clamp the horizontal bars flush together and mark centred half-lap joints 16mm deep and 12mm wide then cut with a tenon saw, chiselling out the waste.
On the vertical bars measure 271mm from the ends and cut half-lap joints, repeating every 265mm
Step 5. Secure the rails and stiles
Apply adhesive to the stile housings then drill 10mm holes 15mm deep, centred 20mm and 45mm from the ends.
Drill 2mm pilot holes the rest of the way through and secure to the rails with screws then plug holes with 10mm dowels, sawing them off flush.
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Traditional oriental screens are easily damaged as the panels are made of rice paper but using frosted acrylic with maple frames modernises this project.
It costs about $700 to make a pair of doors mounted with a 2500mm sliding door kit that has a top guide rail, four wheel assemblies and a track along the floor.
TIP: Buy the tracks for about $80 from a door specialist or hardware store.
Step 6. Attach the frame bars
Apply adhesive to all joints then join the horizontal and vertical bars, position the bar assembly in the frame housings then clamp, drilling 1mm pilot holes to skew-nail the ends of the bars.
Secure the beading to one side of each door frame using only adhesive.