Tim Malyszko

Once those cuts were made, I removed the rest of the material using a straight bit in the router table and cleaned up the little bit left with a sharp chisel.





I then cleaned up the rails by first making an initial cust on the bandsaw and cleaned up the rest with a chisel.

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Next, I set up a 1/4" roundover bit to add a profile to each stile. Here are the stiles after running them through the router:

I then added a recess on the rails so that the shutters would close all the way. This was done using a 1/4" radius round nose bit.


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It's been a long few months since I've updated this thread. I haven't had a whole lot of time to work on the shutters and when I have, I've often rushed something and made a mistake. Here is a rundown of everything done since my first post.

The rails and stiles are being made from Poplar. Since they are 1 1/8" thick, I had to start with 8/4 poplar since I could not find reasonably price 5/4 or 6/4 poplar.

First, I cut a bunch of blanks from the poplar, planed and ...

Creating the elliptical profile was by far the trickiest part and involved a lot of trial and error until I found the optimal setup. Since I owned all the router bit profiles in the woodline set except for the louver provile, I did some searching and found a similar shutter profile from Eagle America (http://eagleamerica.com/architectura...rs/p/174-2805/ Profile O). The bit was expensive at $55, but I am a believer in spending my money on high quality router bits. It however was still cheaper than ...

In the past few weeks, there has been a lot of talk about plantation shutters. I just started on making some for our house yesterday and figured I would document my progress along the way for anyone else that's venturing into plantation shutters.

The louvers will be made from basswood while all the other components will be made from poplar (purchased from creeker Tom Sontag at Lumber Logs).

My first set of plantation shutters will be made for the following window, which ...