|Project by Richforever||posted 08-12-2008 04:35 AM||2978 views||0 times favorited||6 comments|
This was a ”do-it-three-times-to-get-it-right” project.
The first time..... was focused on making rail and stile shutters with recessed panels that were pretty and enhanced the garage. However unfamiliarity with hinges resulted in uneven spacing and non-parallel shutters.
The second time..... was an education in placing butt hinges and using a hand chisel to mortise the hinges. Patience was practiced, but the shutters were unhappy.
The third time..... I jointed the shutters with the router and shims in the outfeed side of the router fence; made all corners 90 degrees; created a hinge mortising template with mdf; bought a workmate bench where I could clamp multiple shutters on edge while mortising the hinges with the router; ripped out and replaced the spacer bars on the left and right sides of the windows; re-installed spacer bars with a level; carved out part of the wall with a reciprocating saw to create enough space for the shutters; rabbeted the center post to make a tight fit; and painted and painted and painted (two coats of primer and two top coats).
The Victorian style casings are made from 1×4 mdf with an ogee edge along the reveal. The backband is 1×2 mdf on edge. A base molding top cap is glued to the 1×4 and against the backband. Corners are mitered and jointed with biscuits. The edges of the sill match the curved ogee on the 1×4’s. The apron is routed with a special 1 1/2” profile bit; and the returns at each end of the apron are 90 degree returns glued together.
One happy garage!!!
-- Rich, Seattle, WA