|Project by clarkey||posted 01-15-2011 10:09 PM||2962 views||12 times favorited||9 comments|
l decided to design and build these Shoji Shutters when we found out to purchase them from the manufacturer was going to cost us three times the amount that it would if l built them myself . So the task began, I had a lot of black walnut that l needed to do something with. My opening for the patio windows was 150 inches so to have two shutters at each end l need a double track 19 feet long. Each shutter had to be 40” X 78 1/2 ” X 3/4 ” so they could overlap by one stile. The stiles are 2 1/2 ” wide, the end stiles are bullnosed and are triple fluted length wise , while the middle stiles are single fluted on each end length wise . The rails are 4 ” wide with the end rails double fluted on the inside and the middle ones double fluted on both sides creating four open panels on each shutter. The panels were completed using a translucent shoji laminated paper 1mm called: Cloud Dragon, it laid in a 3/8” rabbet on the back of the panel held in place with wood stops. In front of the paper is 3/4” lattice held together using half lap joinery. The stiles and rails are held together with Biscuits and Pocket joinery. The shutters and valance are built with Black Walnut with the exception of a Sapele cuff in the middle of valance to cover the seam. The finish is a clear oil base with a three step buffing system.