Custom/Reproduction Shutters

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Project by dynadeuce posted 10-04-2013 09:53 PM 1860 views 2 times favorited 8 comments Add to Favorites Watch

We got the opportunity to to build new replica shutters for a National Register Historic Home in MN. Dissatisfied with what was available from custom shutter builders we decided to do it ourselves. We had the old shutters to model after and purchased a couple of different router bits to get desired profiles and used Rocklers louver pins for shutters and their control arm connectors. We built 18 pairs for a total of 36 shutters. The first picture is PART of the stack ready for drilling a hole in each end. The final picture is of the front of the home.

-- dynadeuce-- What will your legacy be?

8 comments so far

View JAY Made's profile

JAY Made

186 posts in 986 days

#1 posted 10-04-2013 10:12 PM

Wow looks very good. Looks like an exercise in organization. :)

-- We all should push ourselves to learn new skills.

View JustJoe's profile


1554 posts in 980 days

#2 posted 10-04-2013 11:09 PM

That’s a lot of pieces. The result looks great, but I’d have gone crazy before I got the first 3-4 assembled.

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View SteveMI's profile


901 posts in 2236 days

#3 posted 10-05-2013 01:50 AM

Wow looks very good. Looks like an exercise in organization. :) +1

That’s a lot of pieces. The result looks great, but I’d have gone crazy before I got the first 3-4 assembled. +1


View hoss12992's profile


3153 posts in 835 days

#4 posted 10-05-2013 03:33 AM

Great job. Very impressive

-- The Old Rednek Workshop

View jim65's profile


542 posts in 875 days

#5 posted 10-05-2013 04:24 PM

What a job, looks like a lot of work but well worth the effort!

-- Jim, Marostica Italy

View robscastle's profile


2325 posts in 1146 days

#6 posted 10-06-2013 08:49 PM

Very interesting work and impressive final result.
You said you bought a couple of different router bits to produce the profile, I would be interested to know what ones you used and how you produced the finished edge.

I looked into making these type of shutters some years ago as an income producing activity. I thought they looked very impressive on a house, but there was a $25k initial outlay even with your own tools, so I was not able to follow it up any further due to the initial high setup costs.

-- Regards Robert

View dynadeuce's profile


39 posts in 1586 days

#7 posted 10-06-2013 11:31 PM

there is a louver router bit from Rockler about $50 and then we used a core box bit with a diameter that matched a bullnose radius bit. the bullnose edge proflie was mated to the corebox end profiles just as you would make a cope and stick panel. we glued the rails to the stiles and used trim head screws to hold and strengthen the joint. the full list of power tools we used would be table saw, planer, miter saw, router, router table, drill press, drill driver, random orbital sander. We were able to produce them cheaper than the pros and were able to stick closer to the historic design of the original shutters.

-- dynadeuce-- What will your legacy be?

View Underdog's profile


636 posts in 977 days

#8 posted 10-07-2013 02:59 PM

How did you drill the ends of the louvers? Wasn’t that labor intensive?

And how did you put them into the frame after it was assembled?

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