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Domino Jointery Continued...


Here are the rails and stiles all dry fitted together:

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 ...