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The thought of sanding louvers made me shutter!

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Forum topic by AandCstyle posted 11-13-2016 11:06 PM 897 views 1 time favorited 8 replies Add to Favorites Watch
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AandCstyle

2905 posts in 2096 days


11-13-2016 11:06 PM

Topic tags/keywords: jig shutter

I am in the process of making interior plantation shutters for our house. I have completed 2 rooms, the third is in process and 5 rooms remain. Thus far, I have been hand sanding the louvers because they have a curved profile and I didn’t know how to deal with that. However, necessity is the mother of invention and I came up with a Frankenstein jig that works for me.

Here is a pic of the profile:

This is the “jig”.

I attached stops to the clamp with double stick tape to facilitate clamping the louvers at the desired depth.

The clamp is held in place by two scraps into which I cut shallow groves. The two groves aren’t quite as deep as the clamp bar so there is good clamping pressure by the vice. The two pieces of scrap are wider then the clamp so the vise doesn’t clamp onto the clamp. I hope this makes sense.

I used this today for the first time and was able to sand a louver with 150G on the ROS in < 2 minutes. The only additional sanding I will do will be on the edges. I am a VERY happy camper. :) I hope this will be of some use to any future shutter makers.

-- Art


8 replies so far

View Alongiron's profile

Alongiron

638 posts in 2532 days


#1 posted 11-13-2016 11:18 PM

I watched Norm make shuttters on the NYW and I always wanted to try it. I will use your “Frankenstein” method when I am ready. Thanks for your post!!

-- Measure twice and cut once.....sneak up on it! Steve Lien

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Grumpymike

2173 posts in 2154 days


#2 posted 11-14-2016 01:12 AM

I shudder to think of all the sanding involved with all of the slats … (Pun intended, the devil made me do it)
But it looks like you have it solved … I assume that you do not have a milling head and are sanding in the curve, lots of tedious work but you have the tenacity to pull it off.
Looking forward to seeing the finished product.

-- Grumpy old guy, and lookin' good Doin' it. ... Surprise Az.

View OggieOglethorpe's profile

OggieOglethorpe

1276 posts in 1949 days


#3 posted 11-14-2016 12:50 PM

I’m a big fan of using the first example of the parts to make a foam sanding block that matches the profile. Use the first part as a sanding block on the foam to make a reverse profile.

This technique doesn’t work that well for complex moldings with crisp edges or deep recesses, but it works like a champ for shapes like your shutter louvers, bull noses, coves, airfoils, etc…

View isotope's profile

isotope

168 posts in 1463 days


#4 posted 11-14-2016 02:04 PM

Clever trick! Well done sir


I m a big fan of using the first example of the parts to make a foam sanding block that matches the profile. Use the first part as a sanding block on the foam to make a reverse profile.

Very interesting idea. Just curious, what kind of foam do you use?

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AandCstyle

2905 posts in 2096 days


#5 posted 11-14-2016 11:21 PM

Steve, this makes a world of difference. I estimate that I am able to make shutters for two 30”x 70” windows in less than a week, excluding the painting.

Mike, yes, sanding in the curve. They will look like the ones you have already seen, but I can post more pix if you like.

Oggie, the method you suggest works well, but I have well over 600 louvers to sand throughout the entire house and my arm would fall off before I completed them by hand sanding. :D

-- Art

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mahdee

3828 posts in 1606 days


#6 posted 11-15-2016 03:20 AM

I had to look at it twice to get it. Very good idea.

-- earthartandfoods.com

View BurlyBob's profile

BurlyBob

5066 posts in 2104 days


#7 posted 11-15-2016 03:37 AM

I concur with Mahdee. After studying your jig, I like it. I’m going to remember it. I can see where it could be put to good use for other projects. Thanks.

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AandCstyle

2905 posts in 2096 days


#8 posted 11-15-2016 10:52 PM

Mahdee and Bob, thank you!

-- Art

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