Author Topic: Plantation shutter madness  (Read 6547 times)

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Offline DynaGlide

  • Posts: 561
Plantation shutter madness
« on: July 11, 2019, 01:13 PM »
With each project I take on I look to grow my skill set and occasionally use it as an excuse for new tools. This one was motivated by my desire for a CMS router table. After getting new windows in our home the boss and I realized our old interior shutters didn't quite look right anymore. Full of confidence and lacking in wisdom I told the boss I can make new ones. After plenty of mistakes I have a pair of mating shutters mocked up and am going through the monotony of making the remaining pieces to build the rest. I have lots of respect for anyone that does this sort of work often as I'm starting to question my sanity.

Pictures in no particular order





























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Festool USA does not pre-approve the contents of this website nor endorse the application or use of any Festool product in any way other than in the manner described in the Festool Instruction Manual. To reduce the risk of serious injury and/or damage to your Festool product, always read, understand and follow all warnings and instructions in your Festool product's Instruction Manual. Although Festool strives for accuracy in the website material, the website may contain inaccuracies. Festool makes no representations about the accuracy, reliability, completeness or timeliness of the material on this website or about the results to be obtained from using the website. Festool and its affiliates cannot be responsible for improper postings or your reliance on the website's material. Your use of any material contained on this website is entirely at your own risk. The content contained on this site is provided for informational purposes only and does not constitute professional advice.


Offline TSO Products

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Re: Plantation shutter madness
« Reply #1 on: July 11, 2019, 01:31 PM »
@DynaGlide  - you are a brave soul to tackle a project like this. Seeing what's involved makes it easy to leave it to a production shop for our place when it comes place to retire the plastic ones on our Condo.

thanks for sharing what's involved and what is possible!

Hans
TSOproducts.com

Home of the GRS-16 and GRS-16 PE  plus TPG Parallel Guide -  the MTR-18 Triangle - TDS-10 Dog Stop and GRC-12 Guide Rail Connector; Work Holding solutions plus AXMINSTER UJK in the USA

Offline ear3

  • Posts: 3886
Re: Plantation shutter madness
« Reply #2 on: July 11, 2019, 01:36 PM »
That's fantastic -- looks like you really figured out the process.  How long do you think it took to bust those out?
Kapex KS 120 w/UG Cart and Extensions • CXS Set • T18+3 w/Centrotec Installer's Set • PDC 18/4 • TS 75 • TSC 55 • HKC 55 w/250, 420 and 670 FSK rails • Carvex 420 w/Accessory Kit • Domino 500 Set • Domino 700 XL • OF 2200 w/Base Accessory Kit • OF 1400 • OF 1010 • MFK 700 EQ Set • LR 32 • MFS 400 w/2000, 1000, and 700 extensions • Rotex 90 • Rotex 150 • LS 130 • ETS-EC 150/5 • ETS-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/BT module • CT Sys w/Long-Life Bag • MFT/3

Offline DynaGlide

  • Posts: 561
Re: Plantation shutter madness
« Reply #3 on: July 12, 2019, 07:30 AM »
@TSO Products Thank you Hans. It's been a learning experience but I think I've got it all down.

@ear3 I don't even want to speculate  :-X Most of it was figuring out machine setup. All the little details just take time. Like drilling out each louver right in the middle for the control arm fasteners, and again on each end for the louver pins. I haven't even gotten to sanding yet. I can see why custom shutters would cost a lot of money.
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Offline ear3

  • Posts: 3886
Re: Plantation shutter madness
« Reply #4 on: July 12, 2019, 07:36 AM »
@DynaGlide What's the mechanism you're using to open and close them?

@TSO Products Thank you Hans. It's been a learning experience but I think I've got it all down.

@ear3 I don't even want to speculate  :-X Most of it was figuring out machine setup. All the little details just take time. Like drilling out each louver right in the middle for the control arm fasteners, and again on each end for the louver pins. I haven't even gotten to sanding yet. I can see why custom shutters would cost a lot of money.
Kapex KS 120 w/UG Cart and Extensions • CXS Set • T18+3 w/Centrotec Installer's Set • PDC 18/4 • TS 75 • TSC 55 • HKC 55 w/250, 420 and 670 FSK rails • Carvex 420 w/Accessory Kit • Domino 500 Set • Domino 700 XL • OF 2200 w/Base Accessory Kit • OF 1400 • OF 1010 • MFK 700 EQ Set • LR 32 • MFS 400 w/2000, 1000, and 700 extensions • Rotex 90 • Rotex 150 • LS 130 • ETS-EC 150/5 • ETS-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/BT module • CT Sys w/Long-Life Bag • MFT/3

Offline DynaGlide

  • Posts: 561
Re: Plantation shutter madness
« Reply #5 on: July 12, 2019, 07:46 AM »
They will have a control arm going down the middle like standard shutters. If you're interested in more these are based on Rockler's Shutter Design Wizard: https://www.rockler.com/shutter

My mocked up set isn't complete those were for taking width and length measurements. I hadn't routed the mouse holes on the top rails or attached the control arms in that picture.
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Offline BarneyD

  • Posts: 86
Re: Plantation shutter madness
« Reply #6 on: July 12, 2019, 10:22 AM »
Your timing is perfect, @DynaGlide. I'm pretty sure that some of these will shortly be on my radar. Daughter in law has made some  comments. So I've been doing some research and I'm questioning whether I want to tackle something like these. Seems like a whole lot of tedious work. Did you buy the slats from Rockler? They look to be the 3" versions, correct? Were you happy with their jigs, etc.? Thanks for posting.
Barney

Offline DynaGlide

  • Posts: 561
Re: Plantation shutter madness
« Reply #7 on: July 12, 2019, 11:10 AM »
Your timing is perfect, @DynaGlide. I'm pretty sure that some of these will shortly be on my radar. Daughter in law has made some  comments. So I've been doing some research and I'm questioning whether I want to tackle something like these. Seems like a whole lot of tedious work. Did you buy the slats from Rockler? They look to be the 3" versions, correct? Were you happy with their jigs, etc.? Thanks for posting.

@BarneyD Tedious doesn't quite do it justice. While I'm glad to be doing this myself I don't think I'll be doing it again. Although I did agree to do a pair for the upstairs bathroom when I'm done. . .  [doh]

The main movable/fixed jig is all but a necessity as is the louver and control arm jig that comes in the same package. The mouse hole jig is worthless and doesn't work. The jigs work and do their job but if you aren't careful you'll be scrapping one of your stiles (or 2 or 3. .) because you didn't orient the face of the boards properly to the jig. This was an issue for me mainly because my setup requires mating shutter panels but the two middle stiles that come together are different widths to create the illusion that they're the same when the rabbets come together. If you tackle this yourself just make certain to think about all the things that can go wrong and idiot proof the process as much as possible so you don't have to think about what goes where.

If your daughter in laws windows only require one shutter per window then the whole job is much, much easier. Mine require two shutters per window which took the complexity up several notches. 3 1/2" louvers are being used, purchased from Rockler. The cost adds up fast on those. Something to consider if you are capable of making them yourself.

Here are some videos I watched several times while doing my research that I think will help you:





« Last Edit: July 12, 2019, 11:26 AM by DynaGlide »
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Offline neilc

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Re: Plantation shutter madness
« Reply #8 on: July 12, 2019, 01:14 PM »
Matt -

Those look great!  Nice work. Thanks for all the photos.

Offline DynaGlide

  • Posts: 561
Re: Plantation shutter madness
« Reply #9 on: July 13, 2019, 08:37 AM »
@neilc Thank you!

I made some more progress. Drilling the 96 louvers and keeping all of the stiles oriented the right way was really not fun but i got through it with plenty of breaks along the way. Felt a bit like I was addressing Christmas cards. Still need to do Domino joinery then dry fit, sanding, glue up and paint. But that all can wait as I'm headed to the Cape for a week.  [big grin]





« Last Edit: July 13, 2019, 08:42 AM by DynaGlide »
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Offline six-point socket II

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  • aka @the_black_tie_diyer
Re: Plantation shutter madness
« Reply #10 on: July 13, 2019, 08:45 AM »
One word, amazing! Looking forward seeing them finished. :)

Thanks for sharing!

Kind regards,
Oliver
Kind regards,
Oliver

Offline Green Mojo

  • Posts: 55
Re: Plantation shutter madness
« Reply #11 on: July 13, 2019, 09:51 AM »
Those look great. I did shutters for my house also using that Rockler setup. The first few I did totally from scratch including routing the louvers. Not much fun there. Then I found out we had a moulding shop nearby that sold louver slats and also premilled style pieces. With those, it was a breeze to crank them out. Now hanging them was a definitely not a breeze. I’m sure you will enjoy them for many years to come.

Offline BarneyD

  • Posts: 86
Re: Plantation shutter madness
« Reply #12 on: July 13, 2019, 10:06 AM »
Thanks for the links, @DynaGlide.  I'll certainly check them out. Please continue with updates. I'm looking forward to seeing the finished product. Looks great so far. Cheers.
Barney

Offline Bob D.

  • Posts: 1390
Re: Plantation shutter madness
« Reply #13 on: July 13, 2019, 04:02 PM »
Speaking of finish, now that the easy part is done (building the shutters), it's time to paint.

Will you do that before you assemble of afterward?

I remember on the NYW Norm built some plantation shutters a few years back.

-----
It's a table saw, do you know where your fingers are?

Offline DynaGlide

  • Posts: 561
Re: Plantation shutter madness
« Reply #14 on: July 13, 2019, 09:39 PM »
Speaking of finish, now that the easy part is done (building the shutters), it's time to paint.

Will you do that before you assemble of afterward?

I remember on the NYW Norm built some plantation shutters a few years back.



Wow that was involved. Hats off to Norm. I think I'll follow his advice and prime the louvers and probably the rest before assembly and spray everything after glue up. Maybe tape off any glue areas before spraying.
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Offline Kevin C.

  • Posts: 125
Re: Plantation shutter madness
« Reply #15 on: July 13, 2019, 10:00 PM »
 First off, your shutters look really good! There is an insane amount of work involved in them.
 I can tell ya that you will get a much better result if you prime your parts ahead of time. Getting the ends of the louvers and the inside of the styles after they're assembled wont look nearly as good. The shop that I have been installing for (about 20 years now) primes all the parts before it gets assembled.
 When it is time to paint them, put a hook in the top of the panel and hang it so you can spray both sides of the panel at the same time.

Offline DynaGlide

  • Posts: 561
Re: Plantation shutter madness
« Reply #16 on: July 14, 2019, 07:49 AM »
First off, your shutters look really good! There is an insane amount of work involved in them.
 I can tell ya that you will get a much better result if you prime your parts ahead of time. Getting the ends of the louvers and the inside of the styles after they're assembled wont look nearly as good. The shop that I have been installing for (about 20 years now) primes all the parts before it gets assembled.
 When it is time to paint them, put a hook in the top of the panel and hang it so you can spray both sides of the panel at the same time.

Thank you for the kind words and the wisdom. I think I'll do just that. I'll setup a clothes hanger rod for drying and prime everything except glue surfaces before assembly. Lots of firsts for me but I have all the right equipment just need to do some practice runs.
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Offline TSO Products

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Re: Plantation shutter madness
« Reply #17 on: July 14, 2019, 09:24 AM »
- do I hear any votes for Shellac as a sanding sealer before any painting and assembly?

Hans
TSOproducts.com

Home of the GRS-16 and GRS-16 PE  plus TPG Parallel Guide -  the MTR-18 Triangle - TDS-10 Dog Stop and GRC-12 Guide Rail Connector; Work Holding solutions plus AXMINSTER UJK in the USA

Offline Sparktrician

  • Posts: 3838
Re: Plantation shutter madness
« Reply #18 on: July 15, 2019, 07:32 AM »
- do I hear any votes for Shellac as a sanding sealer before any painting and assembly?

Hans

Can't address the use of pure shellac, @TSO Products, but I have used Zinsser B-I-N primer which is shellac-based.  It lays down well when sprayed and sands out to a very smooth base for top coats.   [smile]
- Willy -

 "Remember, a chip on the shoulder is a sure sign of wood higher up." - Brigham Young

Offline DynaGlide

  • Posts: 561
Re: Plantation shutter madness
« Reply #19 on: July 26, 2019, 02:11 PM »
Back at it a little. I waited to do any further Domino work until I got my TDS-10 in from @TSO Products . I had previously done one set of stiles and found it awkward enough that I wanted to wait until these were available to do the rest. For narrow stock getting it to hang off the bench they're perfect. I think they'll find lots of uses around the shop.






For a project of this scope with so many parts when it comes to steps like this I like to take my time doing the first piece, then I keep it nearby for reference so I don't get turned around on which face goes up, at which end, etc. It's easy to catch mistakes before they happen when I work this way. The first stile I did I went off the wrong face and ended up having to repair the mortises by gluing a domino in and flush trimming it off.

Example, I'll grab one of the stiles with the rabbet on the outside to the right that I've already dry fitted and know to work and set it on the bench. Then I go and grab the other stiles with a rabbet on the outside to the right. I match it up with my already Domino'd stile, move it to position and clamp it down and do my mortises. Put it back where I got it and grab the next one. Even though I labeled all the tops, bottoms, fronts, backs it all but eliminates human error from the equation. Less thinking = more better.
« Last Edit: July 26, 2019, 02:43 PM by DynaGlide »
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Offline ear3

  • Posts: 3886
Re: Plantation shutter madness
« Reply #20 on: July 26, 2019, 03:12 PM »
Making progress!

Those TSO stops are pretty slick -- hadn't seen those before.  For situations like dominoing the edge of a long narrow piece basically use the same setup as you do with the clamps, except in place of the TSO I use the veritas stop fences -- they have a lower, sub-1/4" profile, and so when I move over to handplaning or sanding they allow me to work on thinner pieces: http://www.leevalley.com/us/wood/page.aspx?p=69837&cat=1,41637
 
Kapex KS 120 w/UG Cart and Extensions • CXS Set • T18+3 w/Centrotec Installer's Set • PDC 18/4 • TS 75 • TSC 55 • HKC 55 w/250, 420 and 670 FSK rails • Carvex 420 w/Accessory Kit • Domino 500 Set • Domino 700 XL • OF 2200 w/Base Accessory Kit • OF 1400 • OF 1010 • MFK 700 EQ Set • LR 32 • MFS 400 w/2000, 1000, and 700 extensions • Rotex 90 • Rotex 150 • LS 130 • ETS-EC 150/5 • ETS-EC 150/3 • Pro 5 LTD • RTS 400 • RAS 115.04 • RS 2 • HL 850 • Vecturo OS 400 • CT 26 w/BT module • CT Sys w/Long-Life Bag • MFT/3

Offline DynaGlide

  • Posts: 561
Re: Plantation shutter madness
« Reply #21 on: July 29, 2019, 04:53 PM »
Not much shop time as we prepare for my son's 2nd birthday today. I did do a little Weber kettle maintenance though.

I decided to dry fit the shutters and label the matched parts. It's a pretty great feeling when you grab parts from a pile and they all go together perfectly. Lots of sanding ahead of me but I can start to see the finish line. These 36" quick clamps from Bessey I received as a gift for my upcoming birthday came in real handy for fitting each shutter together. Easy to give the handle a little squeeze at a time as you line up all the louvers.









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Offline DynaGlide

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Re: Plantation shutter madness
« Reply #22 on: July 29, 2019, 05:06 PM »
And the obligatory Weber picture
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Offline Bob D.

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Re: Plantation shutter madness
« Reply #23 on: July 29, 2019, 08:14 PM »
Looking good, you've got some time into these already and a ways to go but they are looking great. Yeah, it's nice when you can pick up a random set of pieces and they all fit together like they were milled and fit for each other. You've got your process and machine setup tweaked I would say.

Good to take a break today and spend some time with your Son on his birthday.
-----
It's a table saw, do you know where your fingers are?

Offline Sparktrician

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Re: Plantation shutter madness
« Reply #24 on: July 30, 2019, 08:38 AM »
And the obligatory Weber picture

What's that wearing the burka to the left of the "obligatory Weber"?   [big grin]
- Willy -

 "Remember, a chip on the shoulder is a sure sign of wood higher up." - Brigham Young

Offline DynaGlide

  • Posts: 561
Re: Plantation shutter madness
« Reply #25 on: July 30, 2019, 08:46 AM »
And the obligatory Weber picture

What's that wearing the burka to the left of the "obligatory Weber"?   [big grin]

@Sparktrician Why do I get the feeling you already know the answer to this question  ;D
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Offline DynaGlide

  • Posts: 561
Re: Plantation shutter madness
« Reply #26 on: August 23, 2019, 03:31 PM »
Finally getting off my butt to make a push to finish these up. I've been avoiding the sanding task as I just couldn't figure out a good way to do it. The stiles all have a beading profile on them and I knew I'd have to be careful not to sand off the rounded portion of the bead. I already partially did one on accident so I stopped what I was doing and came up with a fix.

I took one of the scrap test stiles and routed out a rabbet so when clamped it would cover the beading detail and provide a shoulder for my sander to butt up against. Works great. Now just wish I owned the RTS400. I have to do two sides of 16 stiles. . .so 32 times probably starting at 180 and going up to 220. . .hmmmmmm might be time to start shaking some piggy banks. @Sparktrician I know you have every Festool ever made. .mind if I 'ahem' borrow yours?  ;D





« Last Edit: August 23, 2019, 03:36 PM by DynaGlide »
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Offline Sparktrician

  • Posts: 3838
Re: Plantation shutter madness
« Reply #27 on: August 23, 2019, 06:18 PM »
Finally getting off my butt to make a push to finish these up. I've been avoiding the sanding task as I just couldn't figure out a good way to do it. The stiles all have a beading profile on them and I knew I'd have to be careful not to sand off the rounded portion of the bead. I already partially did one on accident so I stopped what I was doing and came up with a fix.

I took one of the scrap test stiles and routed out a rabbet so when clamped it would cover the beading detail and provide a shoulder for my sander to butt up against. Works great. Now just wish I owned the RTS400. I have to do two sides of 16 stiles. . .so 32 times probably starting at 180 and going up to 220. . .hmmmmmm might be time to start shaking some piggy banks. @Sparktrician I know you have every Festool ever made. .mind if I 'ahem' borrow yours?  ;D

Well, @DynaGlide, I really don't have every tool Festool ever made.  I just have those that I use.  I do have the RTS 400, and if you need to borrow it, you know how to get in touch.   [smile]
- Willy -

 "Remember, a chip on the shoulder is a sure sign of wood higher up." - Brigham Young

Offline DynaGlide

  • Posts: 561
Re: Plantation shutter madness
« Reply #28 on: September 10, 2019, 04:15 PM »
Hi my name is Matt and I have a problem. I bought another tool.

After trying to sand these stiles with what I had (ETS EC 125 and Pro5) I realized the RTS 400 REQ would probably work better and it's like it was designed for this task. Using the included edge guard and my scrap piece as a buffer to keep the sander away from the beading profile, it's just perfect. Maybe I'll actually finish these soon?  [big grin] I know, time to join the comedy tour.

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Offline JimD

  • Posts: 409
Re: Plantation shutter madness
« Reply #29 on: September 15, 2019, 08:45 PM »
You are doing a good job, the shutters look great!  I put them in all the windows of my last house but haven't started them in this one.  I put in new plantation blinds in both houses and made the shutters when the blinds started to yellow in the last one.  Hopefully I will get the other projects complete and make them for this one too.

I made a jig like norm uses to staple the control rod to the shutters.  I used MDF for most of them but used softwood for the center where I used a screw instead of a pin to help hold the shutters dimensions.  I don't remember what I did at the corners, I did not have a domino then so it wasn't that.  I might have made loose tenons with a plunge router.  As you said, the big issue is all the louvers.  It takes awhile if you do not have a shop set up to machine them and then sand them, including after finish is applied.

I used white tinted Resisthane and their primer on mine.  It worked very well.  Very durable and easy to apply.  I am using the same finish on a crib now, changing table is complete and crib is done except for final sanding and then finish.  Everything has been sanded but assembly and a few weeks time means it needs a bit of touchup. 

Anyway, good job. 

Offline DynaGlide

  • Posts: 561
Re: Plantation shutter madness
« Reply #30 on: October 06, 2019, 04:11 PM »
Painting has started. This is new territory for me. I'm doing the best I can with the SW Wall and Wood primer through the Fuji Q5 T75 w/ 3M PPS 2.0 setup. The finish comes out gritty but sands smooth with 320 by hand. I'm only on my first coat with the louvers. Still have to do the rest of the parts.





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Festool USA does not pre-approve the contents of this website nor endorse the application or use of any Festool product in any way other than in the manner described in the Festool Instruction Manual. To reduce the risk of serious injury and/or damage to your Festool product, always read, understand and follow all warnings and instructions in your Festool product's Instruction Manual. Although Festool strives for accuracy in the website material, the website may contain inaccuracies. Festool makes no representations about the accuracy, reliability, completeness or timeliness of the material on this website or about the results to be obtained from using the website. Festool and its affiliates cannot be responsible for improper postings or your reliance on the website's material. Your use of any material contained on this website is entirely at your own risk. The content contained on this site is provided for informational purposes only and does not constitute professional advice.


Offline Michael Kellough

  • Posts: 4318
Re: Plantation shutter madness
« Reply #31 on: October 06, 2019, 04:17 PM »
First coat on raw wood? Grain raising?

Offline DynaGlide

  • Posts: 561
Re: Plantation shutter madness
« Reply #32 on: October 06, 2019, 04:20 PM »
Yes raw wood. Could be I'm too inexperienced to say.
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Offline tjbnwi

  • Posts: 6132
  • Cedar Tucky Indiana
Re: Plantation shutter madness
« Reply #33 on: October 06, 2019, 04:32 PM »
Sounds about right on the first coat. 

Tom

Offline DynaGlide

  • Posts: 561
Re: Plantation shutter madness
« Reply #34 on: October 06, 2019, 05:52 PM »
I'll check in after I get a second coat on with the results before I do any top coats. I need these to turn out.
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Offline BarneyD

  • Posts: 86
Re: Plantation shutter madness
« Reply #35 on: October 06, 2019, 05:59 PM »
Looking real nice, Matt. I admire your tenacity on this job. My daughter-in-law got tired of waiting for me to build her some shutters.  She went ahead and ordered some. And I'm glad she did.  Not sure I'd be able to handle a job like that.
Barney

Offline JimD

  • Posts: 409
Re: Plantation shutter madness
« Reply #36 on: October 07, 2019, 07:54 AM »
I am unfamiliar with the products you are using but grain raising after the first coat is the normal response to water based finishes like I use.  It raises with others but not as much.  So you have more sanding to do after the first coat.  Putting shellac (alcohol solvent) on first helps a little but isn't worth the extra step IMHO.  Shellac is great about sealing in knots in softwood, however.  If the primer I used did not also have that attribute I would use a coat of sheallac.

When spraying, I try to resist the tendency to get the finish glass smooth because it inevitably leads to runs when I try.  I prefer a little rougher result and no runs.  With good light, you can see the difference but it is also a bit of a feel that you may develop. 

Offline DynaGlide

  • Posts: 561
Re: Plantation shutter madness
« Reply #37 on: October 09, 2019, 04:11 PM »
@BarneyD Thank you. I'm questioning my sanity every step of the way.

@JimD thank you for the pointers.

I put the first coat on the rest of the parts:





For the 2nd coat on the louvers I decided to up my game a bit using a cheap turntable off Amazon:



After letting the 2nd coat dry for a bit I'm really happy (surprised) with the result:



It's so smooth I don't even think it needs any sanding. The more I spray the more comfortable I get with technique and mixing. This is all new to me. I'm the last person you'd want to paint a room for you but for some reason if you give me an expensive tool I can figure it out. Brushes and rollers and me just do not get along.
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Offline sprior

  • Posts: 448
Re: Plantation shutter madness
« Reply #38 on: October 09, 2019, 05:04 PM »
I see some familiar looking green knobs and fence dogs in the pictures - glad that they're apparently working well for you.

Offline RKA

  • Posts: 1817
Re: Plantation shutter madness
« Reply #39 on: October 09, 2019, 05:37 PM »
I'm the last person you'd want to paint a room for you but for some reason if you give me an expensive tool I can figure it out. Brushes and rollers and me just do not get along.

Are we related?   [tongue] 
-Raj

Offline BeekATL

  • Posts: 1
Re: Plantation shutter madness
« Reply #40 on: October 20, 2019, 10:06 AM »
Great looking plantation shutters, excellent job.  I simply re-sawed 5/4 poplar, planed, sanded, and bull nosed leading and trailing edges of louvers.  From a few paces off you can not tell if they are flat or elliptical louvers. Instead of setting up a jig i used solid brass eyelets to connect louvers to tilt rod.  Did not want to spend the time setting up jig for staple gun.  Look and work great.  I also used tension springs instead of screw to tension louvers.  Found a good source for these plantation shutter parts at shuttermedic.com

Offline DynaGlide

  • Posts: 561
Re: Plantation shutter madness
« Reply #41 on: October 21, 2019, 09:33 PM »
@BeekATL Thank you for the kind words.

I have the first shutter glued up in clamps.





I'm pretty pleased with how it functions and looks. The louvers picked up a squeak from the last time I dry fitted. .must've happened during the priming process. There's some little imperfections that I'm sure only I'll notice. The wife seemed happy with it so I guess that's good. I'll need to work on my process before doing the rest. I used Titebond II Extend and found it pretty runny. I need the open time it affords to deal with all the louvers and I like that it dries clear but I'm open to suggestions. When I'm working with the shutter pieces, the stiles and rails aren't able to stay horizontal and the glue runs out the bottom of the joint which I'd like to avoid. I might try to adjust my workflow on the louvers so I can switch to regular Titebond II. Other issue is the clamps are marking up the primer but I think that'll clean up. Probably wrap them in tape on the next one.

« Last Edit: October 21, 2019, 09:46 PM by DynaGlide »
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Offline tjbnwi

  • Posts: 6132
  • Cedar Tucky Indiana
Re: Plantation shutter madness
« Reply #42 on: October 21, 2019, 10:00 PM »
Very nice sir.

Tom

Offline Gregor

  • Posts: 1475
Re: Plantation shutter madness
« Reply #43 on: October 22, 2019, 05:46 AM »
I'll need to work on my process before doing the rest. I used Titebond II Extend and found it pretty runny. I need the open time it affords to deal with all the louvers and I like that it dries clear but I'm open to suggestions.
Order these and install the louvers after the glue-up of the frame?

Should also make them less squeaky...

Offline DynaGlide

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Re: Plantation shutter madness
« Reply #44 on: October 22, 2019, 06:45 AM »
I'll need to work on my process before doing the rest. I used Titebond II Extend and found it pretty runny. I need the open time it affords to deal with all the louvers and I like that it dries clear but I'm open to suggestions.
Order these and install the louvers after the glue-up of the frame?

Should also make them less squeaky...

The thought crossed my mind. The clearances are pretty tight on these and I've used those spring loaded pins before, not sure they'd fit unfortunately. Makes me wonder why Rockler didn't design around them in the first place.
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Offline JimD

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Re: Plantation shutter madness
« Reply #45 on: October 22, 2019, 02:38 PM »
It's been 10 years or so since I finished my last one in the old house but I do not remember glueup issues.  I had the louvers all stapled to the rod at that point so they were a unit but still had to have their pins inserted in both sides during assembly.  If I was making them today, I think I might put a domino in the center but without glue and use a screw above and below it with plugs hiding the screws.  No glue.  It would be plenty strong and it would eliminate the glue open time concern/issue. 

Offline DynaGlide

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Re: Plantation shutter madness
« Reply #46 on: October 23, 2019, 08:55 AM »
@JimD Thank you for the insights.

I worked out my assembly issues. I changed the clamps I was using to the quick clamps from Bessey to set the position of everything then I transfer it over to parallel clamps to dry overnight. The quick clamps are a lot easier to work with when slowly drawing parts together accounting for the louver pins. The squeak I had on the first shutter was due to a little bit of paint on the louver pins from priming. It'll work itself out over time on the first shutter but the second one I glued up is just about perfect after knocking everything off the pins before assembly.

I came across this video today: http://www.youtube.com/watch?time_continue=312&v=5SB4GFLFoqY

Now I know how the big guys do this stuff. Pretty cool to watch. I did post on my Instagram a short video showing the second shutter opening and closing. Very pleased with it.
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Offline Sparktrician

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Re: Plantation shutter madness
« Reply #47 on: October 23, 2019, 07:12 PM »

I have the first shutter glued up in clamps.


Great job, Matt!   [smile]
- Willy -

 "Remember, a chip on the shoulder is a sure sign of wood higher up." - Brigham Young

Offline DynaGlide

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Re: Plantation shutter madness
« Reply #48 on: October 23, 2019, 08:19 PM »

I have the first shutter glued up in clamps.


Great job, Matt!   [smile]

Thanks Willy. 3 down 5 to go.
Instagram @matts.garage

Offline DynaGlide

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Re: Plantation shutter madness
« Reply #49 on: October 30, 2019, 04:01 PM »
Matt here. Haven't thrown in the towel yet.

Today was meant to be the finish everything day. Best laid plans and all of that. The morning was eaten up by these control arm hooks:





By the time I had all of those in and after a few four letter words it wasn't until 1PM that I had my spray 'booth' set up. I took it all down for the past two weeks so my wife could go back to parking in the garage. It isn't pleasant to setup alone. To tackle spraying these assembled I went with cup hooks screwed into the bottoms of each shutter. Cheap hangers doubled up and hung on a returned/open box coat hanger tripod thing from Amazon Warehouse. Counter balanced it with two of the old shutters. It wasn't the most stable setup but hey it worked.



It took me a while to get into a groove of how to spray something with so many pieces all the while it wanted to sway on the coat hanger depending on where I was spraying. Fun stuff.

They're all resting in the shop with one coat of S-W ProClassic Alkyd. I'll put the second and final coat on in a few days.



Instagram @matts.garage

Offline neilc

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Re: Plantation shutter madness
« Reply #50 on: November 03, 2019, 12:04 AM »
Looking great, Matt!


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Offline TSO_Products

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Re: Plantation shutter madness
« Reply #51 on: November 03, 2019, 12:58 AM »
Matt, - only someone who has done what you have, can fully appreciate your accomplishment - first time around - no less! If there is a more challenging piece of woodwork to paint than these movable plantation shutters - i don't know what that would be.

My hat's off to you for your patience and persistence - really!

Perhaps you feel like posting a "Lessons learned" to share with others here on the FOG. I'm sure it would be helpful and inspire others.

Hans


Offline tjbnwi

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Re: Plantation shutter madness
« Reply #52 on: November 03, 2019, 01:25 AM »
No wonder your having problems spraying---your T-75 fell apart.......

Looks great Matt.

Tom

Offline DynaGlide

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Re: Plantation shutter madness
« Reply #53 on: November 03, 2019, 06:12 AM »
@neilc Thanks Neil! I'm still loving the vac sys cart. It saw a lot of use on this project. I store my TSO PGS in the middle section. It's the perfect place for it.

@TSO_Products Thank you Hans. I think I will do a wrap up post when everything is done. There was a very long list of firsts for me during this. I learned a lot and am happy to share.

@tjbnwi 😁 I strip it down after every session. Seems like the only way to make sure it's clean. Takes about 10min in the utility sink.

The good news is painting is done. The finish on the frame pieces is fantastic but I wonder if I put enough on the louvers. It is so tricky to get them coated while installed.

Matt
Instagram @matts.garage

Offline DynaGlide

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Re: Plantation shutter madness
« Reply #54 on: November 05, 2019, 12:13 PM »
I've started in on the install:







There's some tweaking to be done. But overall I'm pleased. The wife hasn't seen them up yet. We're having her parents over tonight for her mother's birthday. I'll be cooking up some lamb chops to celebrate.

I think I'll sit back and enjoy them for a bit before I make any more adjustments and finish painting the hanging strips. Still have to do the children's play room, but those can wait after I saw my son raking a toy car on the shutters that are in there now.
Instagram @matts.garage

Offline Sparktrician

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Re: Plantation shutter madness
« Reply #55 on: November 05, 2019, 07:22 PM »
What an improvement, Matt!  Well done!   [thumbs up]
- Willy -

 "Remember, a chip on the shoulder is a sure sign of wood higher up." - Brigham Young

Offline Gregor

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Re: Plantation shutter madness
« Reply #56 on: November 05, 2019, 07:55 PM »
Nice.

Offline tjbnwi

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Re: Plantation shutter madness
« Reply #57 on: November 05, 2019, 08:09 PM »
Looks very nice Matt.

Tom

Offline DynaGlide

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Re: Plantation shutter madness
« Reply #58 on: November 07, 2019, 02:50 PM »
@Sparktrician @Gregor @tjbnwi

Thank you for the compliments. And to everyone else that has followed along.

I went ahead and installed the rest of them to get them out of my shop.



And with that I can put this behind me. Now to not think about shutters for a good long time. I have some things I want to do to my workshop during the holidays before starting in on an office overhaul. I'm sure I'll be starting another thread when the time comes. It'll involve removing a closet, building a built in desk, some flooring and drywall work. Should only take me about 5 years to complete at the rate I work.  ;D
« Last Edit: November 07, 2019, 02:54 PM by DynaGlide »
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Offline TSO_Products

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Re: Plantation shutter madness
« Reply #59 on: November 07, 2019, 08:25 PM »
Matt,
what a wonderful and tasteful enhancement to the traditional architecture of your home. Anyone can start a project - but you finished it - beautifully!

Enjoy! while  we look forward too your next thread.
Haas

Offline SoonerFan

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Re: Plantation shutter madness
« Reply #60 on: November 08, 2019, 09:39 AM »
@DynaGlide 

Matt,
Terrific work!  Thanks for sharing all the insights you gained from this project and for posting all the very helpful pictures. 

Well done!

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Offline DynaGlide

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Re: Plantation shutter madness
« Reply #61 on: November 14, 2019, 09:23 AM »
@SoonerFan Thank you for the kind words.

@TSO_Products You had asked me to do a wrap up prior. I think I can do that now that I've had some thinking time.

For my situation one of the hardest things to figure out was how to build these shutters so they'd fit my windows. I only have about an inch inside the casing to the window so inside mount which looks the best was not an option. Even if I put hanging strips inside the casing and used wrap around brackets there wasn't enough meat to screw the hanging strips into the window framing. The other consideration would've been that the shutters themselves would be much narrower and with wide 3.5" slats I didn't think it would look right. That left me with mounting them outside the window.

The next hurdle was I had to mount them to the window trim. Had they been designed to be full size covering the entire window the option is to build a square frame to install the shutters to. But we wanted the top window uncovered as our house is up slope from the street at the end of a cul de sac, not worried about privacy. And I was told I wasn't allowed to take the window trim down to replace it with a frame. That really made things tricky. The hinges are flush mount and non adjustable. Any adjustments I needed or will need to make to get the two doors to line up with each other is done via the hanging strips. One of the windows the shutters wouldn't close the gap was too tight so I had to shave 1/16" off each hanging strip and re-mount. To help mount the hanging strips to the existing trim I rabbeted the ends to help hold them square to the trim.

At this point I'm not sure what I can do to make adjusting them easier with the limitations above. I'd love to have the adjust ability of a euro cup hinge and I know one shutter company claims to have come up with a system to use them. I made sure to keep each shutter the same so if I ever do come up with a better mounting solution they should all be interchangeable.

The paint also did not come out the way I had hoped. I picked a Semi-Gloss but what is on there is more of a Satin. I chalk this up to having to thin it so much to spray through my HVLP. I'm already thinking in the summer I'll go back and hit it with a Gloss thinned the same amount to hopefully end up at the Semi Gloss I originally wanted.
Instagram @matts.garage

Offline TSO_Products

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Re: Plantation shutter madness
« Reply #62 on: December 02, 2019, 10:03 PM »
Matt, thanks for your lessons learned recap. I was just re-reqading it and this comment caught my eye:
The next hurdle was I had to mount them to the window trim. Had they been designed to be full size covering the entire window the option is to build a square frame to install the shutters to. But we wanted the top window uncovered as our house is up slope from the street at the end of a cul de sac, not worried about privacy. And I was told I wasn't allowed to take the window trim down to replace it with a frame.

Do you recall WHO told you you that you are not allowed to take the window trim down? - and WHAT reason was given?
Do you not own this home?

Seems to me taking the window down and replacing it woould be well within any reasonablke remodel/upgrade project.

Hans

Offline DynaGlide

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Re: Plantation shutter madness
« Reply #63 on: December 03, 2019, 05:52 AM »
Matt, thanks for your lessons learned recap. I was just re-reqading it and this comment caught my eye:
The next hurdle was I had to mount them to the window trim. Had they been designed to be full size covering the entire window the option is to build a square frame to install the shutters to. But we wanted the top window uncovered as our house is up slope from the street at the end of a cul de sac, not worried about privacy. And I was told I wasn't allowed to take the window trim down to replace it with a frame.

Do you recall WHO told you you that you are not allowed to take the window trim down? - and WHAT reason was given?
Do you not own this home?

Seems to me taking the window down and replacing it woould be well within any reasonablke remodel/upgrade project.

Hans

@TSO_Products


Who told me? Yes I know her very well. I'm sure if you're married you have a boss as well. While we do own the home I'm still at her mercy when it comes to renovations   ;D

Reasons given? Because she said so  [eek]
« Last Edit: December 03, 2019, 05:54 AM by DynaGlide »
Instagram @matts.garage

Offline Sparktrician

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Re: Plantation shutter madness
« Reply #64 on: December 03, 2019, 08:04 AM »
Who told me? Yes I know her very well. I'm sure if you're married you have a boss as well. While we do own the home I'm still at her mercy when it comes to renovations   ;D

Reasons given? Because she said so  [eek]

BA-HAHAHAHA!!!!!   [popcorn] [poke] [popcorn]
- Willy -

 "Remember, a chip on the shoulder is a sure sign of wood higher up." - Brigham Young

Offline TSO_Products

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Re: Plantation shutter madness
« Reply #65 on: December 03, 2019, 08:49 AM »
Matt, thanks for your lessons learned recap. I was just re-reqading it and this comment caught my eye:
The next hurdle was I had to mount them to the window trim. Had they been designed to be full size covering the entire window the option is to build a square frame to install the shutters to. But we wanted the top window uncovered as our house is up slope from the street at the end of a cul de sac, not worried about privacy. And I was told I wasn't allowed to take the window trim down to replace it with a frame.

Do you recall WHO told you you that you are not allowed to take the window trim down? - and WHAT reason was given?
Do you not own this home?

Seems to me taking the window down and replacing it woould be well within any reasonablke remodel/upgrade project.

Hans

@TSO_Products


Who told me? Yes I know her very well. I'm sure if you're married you have a boss as well. While we do own the home I'm still at her mercy when it comes to renovations   ;D

Reasons given? Because she said so  [eek]

OK, Matt, I get it:
the Architect / Interior Designer imposed the restriction regarding the window framing. We all know to respect that kind of guidance  [wink]
That said, looking at the interior pictures of your home I would say good taste resides there - Well done!

Hans

Offline Bob D.

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Re: Plantation shutter madness
« Reply #66 on: December 03, 2019, 09:54 AM »
A lot of work, beautiful results Matt. I am sure the Wife is pleased.
-----
It's a table saw, do you know where your fingers are?

Offline mattbyington

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Re: Plantation shutter madness
« Reply #67 on: December 04, 2019, 01:15 PM »
@DynaGlide just read this whole thread, awesome work!! looks super tedious and EXTREMELY rewarding!!

Matt