Plantation Shutters

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Blog series by Holbs updated 01-30-2018 04:35 AM 22 parts 41643 reads 44 comments total

Part 1: $300 Rockler order sent in today

05-08-2017 12:32 AM by Holbs | 3 comments »

My house windows are…standard issue tract home boring. I need a wood working project that will keep me busy and experience more, could help with friends or clients with their own plantation shutter, and will boost my house value. I decided to run with the Rockler integrated jig system as I have 9 large windows and 3 small windows to do which the jig setup will help with the productivity. Basswood is the preferred wood of choice for plantation shutters. My local hardwood dealer can d...

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Part 2: Removal of drywall returns

05-09-2017 04:49 AM by Holbs | 1 comment »

I guess I’m really going to do this :) No turning back now! As I’ve read, it is best to remove drywall totally and put wood boards back in their place, instead of simply putting boards over the drywall. I assume this is needed for plantation shutters due to their weight so that no sagging get involved. That is what I did tonight upon my first test window. I was hesitant at first (back in the day, I tried to install a large whole house fan for my 1200 sq ft house only to reali...

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Part 3: Style, species and color of casing & shutters decided

05-10-2017 02:31 AM by Holbs | 4 comments »

I love “Craftsman” style casing. Just looks….1910’ish or palace like: strong Ford tough, embolden, structured. That is what I’m going for. Unsure of how far down the rabbit hole to go such as elegant crown molding upon the top.For the species, I picked Knotty Alder. It’s super affordable here on the west coast: 4/4=1.60 and 8/4=1.78. I love how rustic it can be turned into.For the color, I will go a mix of American Walnut and Golden Fruitwood dye sta...

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Part 4: lumber picked up, most parts & material arrive

05-19-2017 05:04 AM by Holbs | 2 comments »

It’s almost like Christmas in my house this week. 90% of needed items arrived this week. I’ll keep a running list (for those in my position of not having any real supplies in the shop):1.) Rocker shutter jig2.) all parts for shutters (nylon pins, hinges, clasps, bead bit)3.) the basswood shutters themselves (I still have to buy my own basswood and make stiles)4.) Bob Smith Industries BSI-201 Clear Quik-Cure Epoxy oz. Combined)5.) Great Planes Epoxy Mixing Sticks)6.) Great Plane...

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Part 5: 2 coats of Shellac, 1st coat of Old Masters Dark Walnut on distressed jambs

05-22-2017 01:32 AM by Holbs | 0 comments »

This is the first time ever jumping into the shellac, distressing, and gel stain (glaze?). I was…skeptical of my aptitude to accomplish this because everything I have done has been simple workshop related projects with no finishing. I know I need experience in such matters. So jumped right into it. ROS sanded via 80 and 120 on my bosch 5”, then 280 on my bosch 6” ROS (only has 280 grit…gotta fix that for 220 later). Dusted off the wood. I applied 2 coats of Shella...

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Part 6: Using Summit HVLP sprayer for 1st coat of Poly

05-24-2017 02:47 AM by Holbs | 3 comments »

I bought this Summit HVLP sprayer over a year ago (ok..maybe 2) when it was on sale, knowing one day I will jump into the spraying of finishes. I used it for the first time ever today. I’m glad to have purchased this easy no frills HVLP sprayer kit because the upper echelon advanced (Earlex, Fuji, etc) sprayers have a lot of options that are beyond me at this time. It’s only 1 stage and everything made of plastic but it works and is a great introductory device. Longevity is n...

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Part 7: Sanded with 400 grit and applied 2nd poly coat for window jambs

05-26-2017 01:58 AM by Holbs | 0 comments »

Ahhh…I feel better now. Much better results after sanding with 400 grit (didnt have anything in the 300 range), vacuuming, and HVLP applying a 2nd coat of 100% poly (instead of my first coat of 15% water & 85% poly). Went a little heavier this time around as well. These are things I have to learn. I do have “Understanding Wood Finishing: How to Select and Apply the Right Finish” by Bob Flexner flexner coming in a couple days which should help. I do see 2 or 3 small ...

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Part 8: Jambs & Stool installed, adjustable story stick, starting on casing

05-28-2017 05:05 AM by Holbs | 0 comments »

Gots the jambs & stool installed and squared up. Used garage sale sign (well, the plastic corrugated stuff) as 1/8” shims which works wonderfully. Either I do not understand how, or I am missing something…but I find it impossible to square up the jambs & stool with a tape measure because the stool itself juts out and then having to bend the metal tape to the exact corner. I just couldn’t do it as I felt it inaccurate. So, I made a adjustable story stick (this is ...

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Part 9: Wood Finish error. I made booboo. Re-do

05-31-2017 02:44 AM by Holbs | 2 comments »

Poly runs. Ug! Maybe I’m lucky to have found out now on easy wood and such small quantities. Not sure what was different between my window jambs & stool boards to these casing boards. But I have runs on the side. Bad. I had none on the jambs. I can only assume, went too heavy causing running drips. How to fix? I can only guesstimate sand down and re-finish. Again, it’s only the sides. But still… Ug. Bob Flexner’s “Understanding Wood Finishing&#...

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Part 10: Window Casing completed. Next, the shutter frame & shutters themselves

06-05-2017 12:07 AM by Holbs | 1 comment »

Installed the casing, stop, frieze, header, and apron and posted on Project section: =============And now the 2nd phase of fun: plantation shutter frames and shutters and assembly and even more finishing.

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Part 11: rough dimensioning the shutter frames

06-11-2017 04:11 AM by Holbs | 4 comments »

Finally got around to purchasing basswood for the shutter frames. 2 10’ x 6.5”ish and 7’ x 6”. Rockler science super computer says to make width at 1 1/6”. So I had to buy what my local hardwood distributor had on hand and that would be 8/4. For future shutters, I’ll have to ask if I can special order 5/4 (which might be pushing it) or 6/4 if those sizes even come in basswood. 8/4 is what I got so that means…my first time resawing! I gots an 20...

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Part 12: I just wasted all this wood because of a simple moronic mistake

06-13-2017 03:23 AM by Holbs | 10 comments »

As stated earlier in my blog entry, I am a newb in the realm of sanding & finishing, coming from the world of plywood and construction lumber for all of my projects. I am learning as I go happily but mistakes will come about. I guess I’m lucky that I messed up this wood for this project now, instead of more costly and quantity of lumber later. I can not use the pieces I dimensioned for this project because I got carried away ROS’ing faces & edges which rounded over below...

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Part 13: Tapered gaps mystery: solved!

06-18-2017 02:52 AM by Holbs | 1 comment »

It was my jointer fence all along that gave me gaps between pieces. I’ll explain: this is a 8” GeeTec 2001 jointer from the era of 8” clone Taiwan jointers. The fence system is popular and works. However, I guess my “technique” was wrong just enough to not be 90 degrees on jointing edges after jointing face. This fence system is “loose” below mid-level, meaning it can slide a hair inwards more than you want it to because it was designed to rotate...

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Part 14: Re-Square window jambs, Charles Neil's trace coating

06-25-2017 04:36 AM by Holbs | 0 comments »

Ah…more time to hit up the plantation shutter project after some work & personal time kept me away.I made a flaw in my window jamb & stool squaring. The sliding story stick was not designed accurately leading me to have over 3/8” gap across 5 feet. Being that there will be 8 plantation shutter frames going in that are only allowed 1/8” gap, this 3/8” gap would not look good. So pulled everything down, de-nailed, and re-squared with 2 long boards & a Quic...

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Part 15: 2nd attempt at sanding pieces: success!

06-26-2017 05:18 AM by Holbs | 3 comments »

Very happy at the end results with this batch. In previous blog entry, I mentioned I was giving a shot at the “trace coat” sworn by Charles Neil. It really helped to determine when to keep sanding, when to stop sanding. Though, I think I messed up the first board in the beginning by wiping 100% pure red food coloring instead of later boards of diluted water: 80% water / 20% food coloring (or so) to give that “haze” of color instead of rich color. If you are intere...

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Part 16: Testing of stain, gel, oil, charred, ammonia, and shellac on basswood. For science!

06-28-2017 03:00 AM by Holbs | 3 comments »

So here goes my 24 hour test run of different ways to play with basswood. I could only play with what was on hand. Top board has no sealing done. This is raw basswood sanded to 240.Bottom board has 2 coats of Shellac sanded to 240 to start off with. 1.) Charred. Top board was charred, brass brushed, wiped with water, then shellac sealed. I was curious to see what happens when you charr shellac. Bottom board was shellac sealed, charred, brass brushed, wiped with water. Who chars s...

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Part 17: Rabbets, beads, ammonia basswood, and miter saw accuracy error

06-30-2017 04:59 AM by Holbs | 4 comments »

Unsure which to pick though it’s down to two finish colors: the 2 coats of Shellac, char, wipe with water or walnut gel stain. Still have time to decide. Ran the rails through the dado stack to create rabbets. Setup the router using the supplied Rockler bead bit. Forgot the ammonia “fumed” basswood yesterday evening so this is actually 48 hour result…kinda blandish hue icky. Apparently, I did not setup my Bosch 12” miter saw correctly though I spent 2 hours...

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Part 18: Drilled dowel holes, applied shellac, charred stiles & rails, wire brushed

07-24-2017 04:00 AM by Holbs | 2 comments »

I am using the Rocker 3/8” dowel jig to drill holes in the stiles & rails. I do not like it. Even though I clamped down the jig, it moves 1/32-1/16” during drill operation at times. My next plantation shutter window, I think update and enlarge my router mortise jig and use a plunge router to make holes/floating tenons. But I’m tired of delays so used it to drill over 100 holes today.I applied 1 coat of shellac, went to store for new propane bottle, used my anti-weed ...

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Part 19: charred & scraped & wiped stiles/rails and louvers.

08-13-2017 03:43 AM by Holbs | 1 comment »

I jacked my elbow last month at my day time job giving me some serious tennis elbow I had it once before and it took forever to fade away so I took it easy til I felt it was ok to do the vigorous scraping that I knew would be required. Here is Saturday results: everything charred & scraped. whew. It’s a workout. Almost the same as hand sanding upon MDF. Gots the frames cleaned up and the louvers. In one of the pictures below, you can see the difference between a charred sur...

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Part 20: Stiles, Rails, Louvers: all assembled ready for HVLP'ing

10-11-2017 02:57 AM by Holbs | 0 comments »

Finally had time to assemble the stiles, rails, and louvers into my 8 section plantation shutter project, after a number of months tackling other life issues.Some things learned up to this point:1.) purchasing slats from Rockler has it’s advantages and disadvantages. The advantage is apparent in that you do not have to mill your own slats. The disadvantage is you do not mill your own slats :) I ordered the slats from Rockler and they came 4’1”+/- x 6 pieces. Well, not a...

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Part 21: first shellac coat applied

01-10-2018 03:47 AM by Holbs | 0 comments »

Now with my saw bench completed and before I start on joinery bench, I best finish my plantation shutter project. I needed a way to vertically hang my 8 shutters while drying. I saw this at a local auction and won it: a portable breakdown’able laundry hanger. Made hooks with my jack chain and 30lb fishing line. It works! Tried out the spray tent which also collapses to a small footprint. Lots of backspray as I did not have the back flap open but with garage door and man door open...

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Part 22: 4 light coats of Sealcoat Shellac and all 8 frames. Looking mighty purdy.

01-30-2018 04:35 AM by Holbs | 0 comments »

I used my Capspray 9100 4 turbine HVLP and gun for the first time spraying Sealcoat shellac onto my frames. I have learned, I have much to learn about spraying! It’s easy to spray a 3” straight piece as I did for my window frame parts, but spraying a large area piece is a challenge for the first time. Experience will hopefully fix that. I tried to hang each frame in the backyard on a post but the actual pressure from the spray gun kept knocking it around until I braced the pie...

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