Greetings:
I have just made a pair of plantation shutters for my bathroom using TNYW plans. I thought others might benefit from my experience:
1. The plans and DVD are very thorough and I had no problem with them but you will have to adjust the measurements to fit your particular window.
2. A simple spreadsheet that allows for a variable rail width will help calculate the correct number of slats for a given window height (assuming 2 1/4″ slats).
3. The jigs work well but they will need quite a bit of fine tuning, particularly with the one that shoots the staples into the slats and the slats into the control rod. The jig to drill the holes in the stiles is unnecessarily complicated. It is much easier to gang the stiles together and mark across for the holes and uses a simple fence on the drill press.
4. Making the slats was the most problematic part of the whole project. Norm uses a moulding machine with custom knives, but if you don’t have one, there is a router bit that you can use. Routing two opposites is straightforward since the slat is flat and firm against the router fence. The problem comes with the opposite corners. I ended up taping a 5% angle wedge to the fence to support the slat. It wasn’t perfect and they needed a lot of sanding. Others reported a lot of wasted material. In the end it worked, but the slats are not as perfect as I would have liked.
5. The plans call for the nylon shutter pins to be put in letter size B holes in the stiles. I followed these directions but the slats are very tight. Others reported similar problems. When I do it again, I will use 1/4″ bit, which is the same diameter as the pin. B size is about 1/128″ smaller and I ended up having to tap them lightly to get them to seat.
6. I sprayed the shutters with CAB acrylic. Don’t even think of trying to hand paint them! It would be very difficult to get an even finish with all the nooks and crannies.
7. I recommend getting stainless steel staples to avoid rust.
I expect that next time around it will all be much easier and they are very expensive to buy.
Regards,
Hastings
Replies
Thank you. I have the plans and the DVD. This is one othe many "to do" - probably two years out but I am keeping notes on feedback.
LB
where did you get the SS staples? thanks
I made wood heater vents, one of these days I'll post pics of the results and the jig I used to cut the angled mortises for the slats, if anyone is intersted...
Dane:Go to:http://www.bestmaterials.com/detail.aspx?ID=14906Prompt delivery too!
thanks...
Yes, pics are a must of the jig and the finished product.
Hi Hastings ,
Those look nice , just out of curiosity how long did they take to make ?
dusty
Dusty:From rough lumber to installed took a week of elapsed time and probably two full days of work time. This does not include the day or so that I took to build the jigs.
If you are going to make more shutters, here is an interesting article and bit set that is affordable and works.
Article
http://www.woodline.com/Download/Plantation%20Shutters.pdf
5pc Plantation Shutter Set (no picture) http://www.woodline.com/p-1774-plantation-shutter-set.aspx
Pin & Tensioner Accessory Kit (no picture)
hoodlinttp://http://www.we.com/p-1775-pin-tensioner-accessory-kit.aspx
Jig:Thanks for the article. The jigs he uses are a lot less complicated than TNYW and seem to work just as well.
Nice job. I am in the process of building shutters for 3 windows. This is a time-consuming project! I milled the slats as follows:
1. planed stock to 3/8 thickness
2. cut 3 degree board for for slat to ride through thickness planer for 2 of the 4 passes needed. Set planer so 1/2 of slat width is milled at a pass.
3. cut 6 degree board for the slat to ride through planer for the remaining two passes (to compensate for previous stock removal). Pay particular attention to be sure you are milling the correct quarantile.
4. finish by easing the edges with 1/8 roundover bit at the router table.
This procedure is described in a very old (probably 20 years ago) FWW article on plantation shutters.
FWIW.
Dennis, do you have a good source for the shutter hinges. What type of hinge did you use. I am concidering chrome on brass hinge, but they are $. Do you think stanless steel staples are necessary, or are galvanized ok.
thanks
Jump, I bought fairly inexpensive no mortise hinges from Rockler. They work fine. The hinges are not exposed that much anyway. The hinges are very easy to install since there is no mortising. I used Senco galvanized staples. Stainless steel would be a bit of overkill IMHO.
Good luck with your project! Plan to spend more time than you would think, but the finished product is worth it.
Dennis
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