Making Shutters?

[Ron Kurzius]

Hello all,

I'm going to make 22 shutters and was wondering if anyone had any great ideas that could ease the pain. The last time I did 8 of them and I bought some 5/4 Fir decking for the slats, ripped it into thirds and then ripped those in half and then through the planer to 5/16. It didn't seem to bad at the time I think there were 140 of them, with this new order there are more then 700.

The last time I did MT joints but this time I'm thinking about dowels, I figure there will be 264 dowels, lot of doweling.

So any one have any thoughts other then I'm nuts :)

[Dave Richards]

Are these shutters with moving slats or fixed?

[Ron Kurzius]

Fixed, 20 3/16X 62" shutter size, slats are 17 5/8X 1 3/4X 5/16

[Mel Fulks]

If you don't have CNC or access to one of the old machines that cut the mortises for the slats with round edges, you can
make the old style bevel edge slats and cut the slots in the stiles with dados guided by a ratchet stick. And that older type
looks better.

[jack forsberg]

As Mel said you can't bet the old louver grovers. that said you did not say interior or exterior and some designs are no good on the exterior,

you can cut dowels on the end with simple jigs and this is stronger than drilling into the thin louver for a pin.

297108

297109

if you can find this hardware and there interior it sure would make finishing easy.

297110

[Keith Outten]

A long time ago there was a great set of plans for making shutters in Woodsmith magazine. They had a set of router jigs that you build to make the process faster and more accurate. A friend of mine made interior shutters for his home using the Woodsmith plans.

[Dave Richards]

Mel's suggestions are good. I don't have a CNC machine in my shop so I'd probably set up the Router Boss to make the mortises. They could be through cuts on the center layer of a three-layer glue up or simple angled mortises. If you wanted to use a router to make these mortises, it would be fairly simple to design a set up to make those mortises or angled dadoes.

I've got a book that shows a plan for a router-based mortising jig that puts the router on a long trammel arm. The router swings through an arc of maybe 1 degree and makes a curved mortise but it is so close to straight that it works fine that way.

[Von Bickley]

22 shutters & more than 700 slats.

I would probably start back drinking and smoking......

[Ron Kurzius]

I made the jigs the last time for the router and will be using those. These are exterior shutters duplicating what is there. I made the first 8 out of vg fir because I don't have much faith in modern day pine. So I have a system down, mostly looking for something I may have missed or not thought of to make it easier.

[jack forsberg]

I made the jigs the last time for the router and will be using those. These are exterior shutters duplicating what is there. I made the first 8 out of vg fir because I don't have much faith in modern day pine. So I have a system down, mostly looking for something I may have missed or not thought of to make it easier.

these are how they were made but there where a slue of machines for all the processes not just the grovers


https://www.youtube.com/watch?v=PChKBVHY04I

[Peter Kelly]

I wonder how complicated it'd be to create an indexable angled mortising jig for a Domino.

[Mel Fulks]

I've seen them done with the router jigs,and they worked fine. I do think the ratchet and dado system is faster, especially if
using white pine instead of fir. Less tear out. We used to make some of them with an applied narrow moulding that covered the line of dados. I worked for a company that had a machine like Jack posted that was at least 80 years old and
starting to need work and took up a lot of space. They replaced it with a modern much smaller machine. Smaller was good
since only a couple of years after they bought it the plastic and aluminum shutters took over. When you have no work to
do....the smaller expensive machine is at least less in the way.

[jack forsberg]

I've seen them done with the router jigs,and they worked fine. I do think the ratchet and dado system is faster, especially if
using white pine instead of fir. Less tear out. We used to make some of them with an applied narrow moulding that covered the line of dados. I worked for a company that had a machine like Jack posted that was at least 80 years old and
starting to need work and took up a lot of space. They replaced it with a modern much smaller machine. Smaller was good
since only a couple of years after they bought it the plastic and aluminum shutters took over. When you have no work to
do....the smaller expensive machine is at least less in the way.


here a home made job that's small Mel


https://www.youtube.com/watch?v=qUJzuM3PRAI

[Bruce Wrenn]

Why not do loose tenons instead of dowels? Build a horizontal slot mortiser for rails and plunge router jig for the stiles. Woodsmith / ShopNotes have done a couple of mortising jigs that you could use to both rails and stiles

[ed vitanovec]

Rockler has jigs to make these, you should take a look.

[Kevin Womer]

Rockler has jigs to make these, you should take a look.


+1
I took a look at the jigs they offer, the slats you can buy, and the router bits to make the slats if you wish over the summer for myself and they look like time savers if you are making enough shutters to offset the costs. BTW I am not affiliated with Rockler in any way, just trying to help out.

[Charles Lent]

The Leigh FMT jigs have a template guide available that allows you to cutthe diagonal shutter slat mortises very easily. The template is very reasonably priced, but the jig may not be worth buying if you are buying it just to make a few shutters. Still, their jigs do such a great job of cutting mortise and tenons that you might be able to justify getting one for this, and future projects. I made raised panel shutters for my home and used my FMT Pro jig to do all of the mortise and tenon work on them, but I already had my FMT Pro jig before starting my shutter project.

Charley

[Alden Miller]

I made shutters for a house quite a while ago when I didn't have the setup that I have now. I made a plywood channel to hold the stiles in place and attached a template to it for the router at the angle I wanted the mortise. Then I used a collar on my router to guide it in the template. I cut a series of blocks that where used as spacers between the slats. Cut mortise, add spacer block cut mortise... For the slats I did as you did and then cut the tenons from a pack of slats ganged together on the saw.

-Alden

[Mark W Pugh]

Rockler has jigs to make these, you should take a look.

Anyone actually use one of these jigs?

[Frank Drew]

Why not do loose tenons instead of dowels? Build a horizontal slot mortiser for rails and plunge router jig for the stiles. Woodsmith / ShopNotes have done a couple of mortising jigs that you could use to both rails and stiles

With a horizontal slot mortiser you could do all the mortises -- those in both the rails (end grain on) and stiles, and the angled ones for the slats, using a tilting table or shop made ramp set for the correct angle.

[Alan Bienlein]

I used the jig Norm makes to make a set of louvered doors. I got the video as close as possible to where he makes the jig.

http://youtu.be/_HGwODXgLBo?t=13m23s