Shoji screens are a traditional form in Japanese construction. These screens are used as doors and window screens, to divide rooms, control light, provide privacy and for other purposes. The basic idea of the screen is a wood frame with an interior grid pattern. This interior grid is covered with rice paper and tightened until the screen has a translucent appearance.
Instructions
1. Install a 3/4-inch wood face on your table saw and a dado set. The wood face will allow you to adjust the dado blade height height more easily. Set the height of the dado at 1-inch and the depth from the wood face at 3/8-inch.
2. Cut the rabbet by positioning the 2-inch board flat on the table saw with the length of the board against the wood face. Cut all of your rabbets without adjusting your saw. You may use three beech boards for a single door frame.
3. Measure and cut the lengths of your door frame to the size you are building. Butt your joints together. Use carpentry glue on each side of your butt joint. Drill pilot holes through the end of your joints and use long wood screws to create tight corners. Wipe off any excess glue that squeezes out.
4. Measure and cut your simulated divided light grills to fit inside your rabbet using a coping saw. You should use two grills per door since you will sandwich rice paper between the mullions. Lightly sand your grills and your door frame. Make sure there is no glue remaining on your door frame wood.
5. Stain your door frame and mullions and window trim pieces using a wood stain, rag and small paint brush. Apply the stain in the direction of the wood grain and wipe off to achieve the color you desire. Allow the stain to dry based on the manufacturer's recommendation. Most stains will dry in 24 hours.
6. Apply a sealer or finish treatment over your wood stain using a paint brush. Allow the sealer to dry completely. Most sealers will dry in 24 hours.
7. Lay your door frame with the rabbet side down. Insert one mullion grill panel so that the smooth side is up. Use a few brad nails and a small hammer to attach the grill to the door frame. Be careful not to nail into the rabbet.
8. Paint rice glue over the flat surfaces of the mullions using a 1/4-inch artist paintbrush. Unroll the rice paper and attach it evenly from the top of the door frame to the bottom. If your door is wider than the paper, create a seam in the middle of one of the vertical mullions. Trim off any excess paper.
9. Lay your second mullion grill section on your workbench with the flat side up. Paint rice glue over the flat surfaces of the mullions using a 1/4-inch artist paintbrush. Lift up your grill section and turn it over so that your glue is facing down. Position your mullion grill over and against the rice paper and mullions already mounted in the door frame. Press the mullions firmly into the rice glue.
10. Cut 1/2-inch (pre-stained and finished in step 5) window trim with a coping saw to fit over your mullion grill. Use small brads and a hammer to attach the trim to the door frame. Allow the rice paper glue 24 hours to dry completely.
11. Stand your door frame against a wall. Plug in your hair dryer. Lightly mist the rice paper with water from a spray bottle and dry the rice paper with your hair dryer. This should shrink the rice paper and give it a taut appearance.
Tags: door frame, rice paper, your door, your door frame, mullion grill, wood face, rice glue
