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Old 01-08-2012, 10:05 PM
Tom Gensmer Tom Gensmer is offline
 
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Location: Minneapolis, Minnesota
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Default EZ Shutters

Ok, in this thread I will be posting photos and videos of a project I am working on where the customer wants me to modify their window shutters.
To start with, the existing shutters on the house are roughly 6í tall, running from the soffits down to just above grade.

The customer requested that I modify the shutters so that they would be the same height as the windows, and that the center rail be centered on the window.

To achieve this, I needed to cut off the tops and bottoms of the shutters, remove slats and install new rails at the tops and bottoms.

The first two photos show the shutters as they were when I started work.

In the next photograph, you see that I have my EZ-One ready to cut the top and bottom of a shutter.


Here is a link to a video of me cutting a shutter. I am finding that I REALLY want a longer fence, and intend on ordering a longer SSME, SME's, and more Squaring Stops so I don't have to spend so much time fussing with squaring my material.

http://www.youtube.com/watch?v=vCjHdGQR4Ec
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Old 01-08-2012, 10:06 PM
Tom Gensmer Tom Gensmer is offline
 
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The next photo shows the cut shutter.

I used a Multimaster to remove the top and bottom two slats to make room for new rails.

After cutting I used my RO90 to clean up the cuts and get them ready for glue.
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Old 01-08-2012, 10:07 PM
Tom Gensmer Tom Gensmer is offline
 
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Now for the new rails. I forgot to take photos, but basically I set up my EZ-One with a stop set to cut the 5/4x4 Clear Cedar stock and cut all of my pieces to length.
I then set up my Kreg jig to cut pocket holes. If Iím only cutting a few holes I donít bother with chip collection, but with over 100 holes to drill it was worth the few seconds it took to hook up my dust extractor. I have found that by sucking out the chips the drill works more quickly.

The following two videos show me drilling pocket holes. It may be difficult to see, but I used the sliding stops on my Kreg jig set up to set exactly where the holes are drilled.
http://www.youtube.com/watch?v=KScP9xxFt3k
http://www.youtube.com/watch?v=Ck9VqSEZN7w
This next video shows me routing a 1/8Ē round over on what will be the inside edge of the rails. Youíll notice that I have the Kreg sliding stops set up like a jig to hold the pieces.
http://www.youtube.com/watch?v=2030OoLAzUY
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Old 01-08-2012, 10:09 PM
Tom Gensmer Tom Gensmer is offline
 
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The next photos show how I now have the new rails glued, screwed and clamped together. I used Titebond Type III glue for this project, as it is waterproof. Youíll see that I never bothered to rip my rails to width. This was on purpose.
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Old 01-08-2012, 10:11 PM
Tom Gensmer Tom Gensmer is offline
 
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In this last series of photos you see how I used the EZ-to to trim off the bottom of the rail flush with the bottom of the stiles. I actually trimmed roughly 1/32Ē off the bottom of the rails as well, just to make sure everything was nice and flush.

http://www.youtube.com/watch?v=Hfz38bcWLOE
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Old 01-08-2012, 10:23 PM
Tom Gensmer Tom Gensmer is offline
 
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....And after filling some holes and a coat of primer, here are pics of the end product. The shutters still need a coat of paint, but the customer is still debating if they want to keep the shutters or go with grids in the windows, so we'll wait until Spring to decide if they want to keep them or not.

I hope this little walk through was helpful, please post with any questions or suggestion!
Best,
Tom
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Old 01-08-2012, 11:03 PM
Gsharp8 Gsharp8 is offline
 
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Hey Tom,

Nice thread, pics, and work. Great to see someone find the ways to make the table do what you need.

I would love to know about the setup with the Kreg pocket hole and stops...?? what is the board they are on and how do you use it? Is it that size for a reason? got any good pics of that setup?

Greg
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Old 01-08-2012, 11:16 PM
sean9c sean9c is offline
 
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Nice job.
I have to say that those long shutters are the dumbest looking architectural detail I've seen in a while. It was probably what they could buy.
I wonder who decided that phony shutters looked good? Dump idea, all the joints make them rot quickly, they're a PITA to paint and when you get sick are tired of them and want to get rid of them you're stuck with a bunch of holes in your siding.
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Old 01-08-2012, 11:24 PM
Tom Gensmer Tom Gensmer is offline
 
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Quote:
Originally Posted by sean9c View Post
Nice job.
I have to say that those long shutters are the dumbest looking architectural detail I've seen in a while. It was probably what they could buy.
I wonder who decided that phony shutters looked good? Dump idea, all the joints make them rot quickly, they're a PITA to paint and when you get sick are tired of them and want to get rid of them you're stuck with a bunch of holes in your siding.
LOL, preaching to the choir buddy! Every time I handle non-operable shutters I have to restrain myself from telling the homeowner that technically they are installed backwards, and to look accurate they should be installed with the slats pointed towards the house.... yeah, always a losing discussion, I've learned to just perform the work and suggest that if they change their mind things can always be changed in the future!
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Last edited by Tom Gensmer; 01-08-2012 at 11:27 PM.
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Old 01-08-2012, 11:26 PM
Tom Gensmer Tom Gensmer is offline
 
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Location: Minneapolis, Minnesota
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Quote:
Originally Posted by Gsharp8 View Post
Hey Tom,

Nice thread, pics, and work. Great to see someone find the ways to make the table do what you need.

I would love to know about the setup with the Kreg pocket hole and stops...?? what is the board they are on and how do you use it? Is it that size for a reason? got any good pics of that setup?

Greg
Thanks for the comment Greg! I'll take some photos of my Kreg set up sometime next week. Thanks!
Best,
Tom
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