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Project by AandCstyle posted 09-07-2016 01:01 AM 1891 views 5 times favorited 18 comments Add to Favorites Watch

This is really more of a proof of concept project than a completed project. I used the Rockler shutter templates and hardware, although I was able to find the hinges cheaper on Amazon. I wanted to try this and see if I could do it to my satisfaction. This is the one window completed and there are eleven more to do. There are many small pieces and even more repetitive functions. As an example, there are 36 louvers in this set of shutters. Each louver has to be run by the router bit 4 times to obtain the desired profile, Then there is the sanding which is mostly by hand because of the small size of the louvers and the curved profile. The wood is poplar and it is much easier to work than my usual qswo.

Another challenge is that I really didn’t know how it would all work out until the shutters were complete. I am not able to test fit things together because there are plastic pins that fit very tightly into holes and I tested one and was barely able able to pull it out again. I didn’t want to finish the pieces with the plastic pins in place so it was a bit of an adventure.

Yesterday I finished spraying the third and final coat of Target’s EM6500 on the individual pieces and assembled them. There was a bit of a learning curve with this product, but I am happy with the results. Hopefully, you will be able to see the finish in the third pic well enough to get an idea of how it looks. This morning I applied the hardware-hinges and hidden control arms and hung them in the bathroom window. I had to wait until it got dark this evening to get decent (for me) pix.

You can see in the third pic that the window frame isn’t quite square so the shutters are a bit tighter together at their tops than at the bottoms. I am willing to live with that 1/16” discrepancy.

I have some other projects to keep me occupied, so I think I will try to complete a window or two a month, or so, and will work on the other projects to give myself a break from the boredom of all the repetitive tasks associated with the shutters. It may be a year before this project is truly complete.

All in all, we are quite happy with the look and greatly prefer it to the mini blinds that were there until this morning. :)

Thanks for any questions or comments.

-- Art

18 comments so far

View Jim Jakosh's profile

Jim Jakosh

24923 posts in 3905 days

#1 posted 09-07-2016 01:09 AM

Nice work . It is good to make proof of concept piece first before cutting up all the wood. They turned out real nice!!

Cheers, Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View JPJ's profile


819 posts in 3420 days

#2 posted 09-07-2016 04:51 AM

Nice job!

View kenfire14's profile


1 post in 1578 days

#3 posted 09-07-2016 05:17 AM

Nice work. I’m in the middle of a shutter project myself and there is definitely a learning curve. Looks like you’ve done a great job!

View Alongiron's profile


654 posts in 3493 days

#4 posted 09-07-2016 11:43 AM

I remember Norm making shutters and I always wanted to give it a try!

Great job Art!

-- Measure twice and cut once.....sneak up on it! Steve Lien

View Halc's profile


146 posts in 2402 days

#5 posted 09-07-2016 01:41 PM

I think they look great! It’s good to know Rockler’s kit worked for you, I’ve always wondered about it. I guess you don’t buy it if you don’t like milling boards.

View splintergroup's profile


3850 posts in 2022 days

#6 posted 09-07-2016 01:46 PM

Ahhh!, nothing says you couldn’t have used QSWO for this you know 8^)

I made a louver for an A/C vent out of Popular, 18” x 18”, 6 slats. That was enough repetition for me.

With 11 more to go, you’ll need to ‘jig-up’ for those slats (I made a carrier for my DS).

The joy of working on a house where nothing is ever identical or square 8^(

That is some top notch work Art!

View pintodeluxe's profile


6173 posts in 3613 days

#7 posted 09-07-2016 02:57 PM

They look very sturdy and handsome too. These will be great for passively controlling house temperature.

I know you say you’re retired, but this looks more like full time production!

-- Willie, Washington "If You Choose Not To Decide, You Still Have Made a Choice" - Rush

View helluvawreck's profile


32122 posts in 3666 days

#8 posted 09-07-2016 06:31 PM

Art, it’s a very nice plantation shutter. Nice work. Incidentally, before we lost our molding plant to a fire we used to make all of the moldings for these shutters and would also basecoat them with white primer. We supplied these moldings to shutter makers all over the southeast. If there is a market for these plantation shutters in your area I would bet that there will be someone making the moldings for these. If you could locate a supplier you could save a lot of work.

helluvawreck aka Charles

-- helluvawreck aka Charles,

View AandCstyle's profile


3283 posts in 3057 days

#9 posted 09-07-2016 08:50 PM

I thank everyone for the kind comments.

Steve, they aren’t difficult, but it does get monotonous which is why I will do a bit at a time.

Hal, if I didn’t like milling boards, I probably wouldn’t be a woodworker. ha

Splinter, I wanted to use qswo, but couldn’t bring myself to paint it white and that is the color the decorator decreed. Besides, the poplar is soooooo much easier to work.

Willie, it is production, but I am doing it by choice so it fits with the retirement thing.

Charles, thanks for the tip. However, being retired I have more time than money. :)

-- Art

View Sausage's profile


33 posts in 2251 days

#10 posted 09-07-2016 08:54 PM

Hi Art,

I have done about 6 windows so far using the Rockler kit as well. I found using popular on the louvers I got alot of tearout. I switched to basswood and the router cuts them a lot better. From what I understand basswood is mostly used for the louvers. I also do a couple of projects with a window shutter set in between. It feels like work making the shutters but they do turn out very nice. Especially when you get a square window frame every now and then..;-)

View AandCstyle's profile


3283 posts in 3057 days

#11 posted 09-07-2016 09:01 PM

Sausage, I didn’t have any tear out, maybe because the bit is new and sharp. I am using quartered poplar so that might have some effect as well. In any event, I will watch for tear out. Thank you.

-- Art

View Grumpymike's profile


2441 posts in 3115 days

#12 posted 09-07-2016 09:51 PM

This is really more of a proof of concept project Proof huh? yep ya proved it to me that you can do it just fine.
Great job on the shutters, and I agree with the decorator, off white is the way to go here … it will make the other wood in the room stand proud.

-- Grumpy old guy, and lookin' good Doin' it. ... Surprise Az.

View Luddite's profile


238 posts in 2038 days

#13 posted 09-07-2016 11:46 PM

12 windows? I “shutter” at the thought. At least it’s not “curtains” for you Art.
A very challenging set of projects well done.

-- T Loftus -- Just on the edge of common sense

View splintergroup's profile


3850 posts in 2022 days

#14 posted 09-08-2016 01:17 PM

12 windows? I “shutter” at the thought. At least it s not “curtains” for you Art.
A very challenging set of projects well done.

- Luddite


Ok Luddite, I was trying to think of something to pun up Art’s latest, but I bow to your punaciousness!

That was just too perfect!

View GR8HUNTER's profile


7643 posts in 1512 days

#15 posted 09-08-2016 04:01 PM

I remember Norm making shutters and I always wanted to give it a try!

Great job Art!

- Alongiron

ME TOO …........ LOL

-- Tony---- Reinholds,Pa.------ REMEMBER TO ALWAYS HAVE FUN

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