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The Work
in Progress Page is an opportunity to share the day-to-day evolution
of some of the various pieces that I design and construct in my
studio. The page will change as new pieces develop, so please visit
often.
The current
Work in Progress piece is a pair of sliding Shoji Screen Doors for
a contemporary Japanese-American home. The doors are used to create
a feeling of privacy in a traditional Tatami room.
Traditional
Japanese techniques of making shoji include hand-cut mortise and
tenon joinery and hand-planed surfaces. The doors are made from
an enormous plank of clear white pine, assuring consistent color
and grain. The grid-work within the frames, called Kumiko, creates
a rhythmic, balanced design. The Kumiko is joined with very precise
fitting half-lap joints, cut with a special saw called a dozuki
(Japanese back-saw). All Kumiko pieces are unglued, held together
by tension alone. They are hand-cut one at a time with a Dozuki
saw and fine Japanese chisels. The pine is left unfinished allowing
the color of the wood to become richer over time. The high level
of craftsmanship and focus that this type of joinery requires is
a very rewarding aspect of shoji screen projects.
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The
rough-milled pieces of the Shoji Doors. The stacked rectangular
pieces will be joined edge to edge, creating wide panels for
the 'Hip Boards' at the bottom of the doors. Eventually, the
wide panels will be hand surfaced with a traditional Japanese
smoothing plane to fit the matching grooves in the frame. The
longer pieces will become the stiles and rails or framework
for the doors.
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The
kumiko (gridwork) pieces being assembled. The Kumiko is joined
with very precise fitting half-lap joints, cut by hand. No glue
is used in their assembly.
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The
shoji doors installed, open. View is looking into tatami room.
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The
doors installed. View from inside tatami room.
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The
shoji doors installed into the wooden track traditionally used
in Japanese homes.
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The
Kumiko and frame pieces are completely assembled. Hand-made
Japanese paper is attached to the Kumiko with rice glue and
can easily be repaired or replaced. Traditionally the paper
was replaced at the beginning of the New Year. Its translucent
quality softens a room while allowing for privacy. Hand-made
papers are available in a range of colors, textures, and patterns.
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These
Japanese Sword Steel chisels, made by master blacksmith Chuttaro
Imai, show the beautiful folded steel forge welded to a very
hard, high carbon tool steel cutting edge. These chisels are
used to cut the mortises in the Shoji framework as well as the
joinery of the kumiko. The exceptional quality rip-cut dozuki
saw is hand-made by the saw maker Juntaro Mitsukawa and is used
for much of the joinery including the accurate kumiko joinery.
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A
very special Japanese hand plane (kanna) used to smooth all
pieces of the white pine Shoji Doors, leaving a smooth, vibrant
surface. This plane was made in 1999 by master blacksmith Imoto
Masao in celebration of being proclaimed, at the age of 90,
a Japanese "National Living Treasure". Mr. Masao calls
the plane Dai Dogyu, Dai meaning 'big' and Dogyu in this case
representing 'water buffalo' and meaning 'from the earth'. This
is a very difficult steel to work with and has qualities of
being exceptionally hard yet supple, which demonstrates Mr.
Masao's incredible skill level, creating a blade combining both
qualities.
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Detail
view of the Sword Steel chisels showing the wood grain effect
of the folded steel and Mr. Imai's signature. The area where
the the softer and harder steels are forged together can be
seen as lighter and darker grey colors on the chisel's beveled
edge. The softer steel provides resiliency to the very hard
cutting edge.
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