Build Your Own Japanese Sliding Doors

Use 12 x 9mm splayed beading cut with 45º 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.

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.

For precise routing use a Dremel rotary tool with a router attachment.

Use sash clamps or smaller pairs for assembly, applying equal pressure.

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.

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.

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.

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

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.

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.