|Project by sugarpine||posted 01-26-2016 11:49 PM||813 views||1 time favorited||3 comments|
The Rockler fixed shutter jig that I used to rout the louver mortises is designed for 1-1/8” thick stock. The adjacent panel above the opening was 3/4” thick. The panel is designed to be removable, held in place with rare earth magnets. Since the back is never exposed it was a simple matter to rabbet the edges of the 1-1/8 thick frame to make the panel appear to be 3/4” thick. The challenge was being able to install the louvers AFTER the frame and louvers were stained and finished. Staining and finishing after assembly was out of the question. A 3/8” X 3/8” rabbet on the stiles allowed the louvers to be installed from the back. I ripped one side of each louver at an angle to make them flush with 3/8’ rabbet, slipped them in the former mortises, now slots, then pin nailed a 3/8” X 3/8’ retainer in place. The rare earth magnets were installed flush. Rather than install corresponding rare earth magnets in the left and right cabinet fascia pieces, I installed 1/8” x 3/4” metal flat stock, eliminating the need for precise placement of magnets.