Plantation Shutters

[johnh]

We have a bay window in our home. My wife wants to buy plantation shutters for this window opening. After a trip to Lowes, and the shock that ensued when I discovered they wanted $900-$1700 for the options they offered, I have decided to research what it would take to make my own... possibly using the bot for what makes sense.

Anyone here ever made them? Is there a source for prefinished slats by chance? Any advice or jigs on drilling the slat-side pivot pins uniformly?

Thanks in advance for any help you care to offer, whether it's materials, jig examples, or past projects!

http://www.blinds.com/images/product/newpictures/thumbnail_1277327729.jpg

[Kyle Stapleton]

Norms done everything.:)
http://www.newyankee.com/index.php?id=53#!/~/product/id=7916664

[Bob Eustace]

If its any help John, Rockler have all the bits and pieces including jigs. These would be easy to make on the bot I reckon.

[steve_g]

John…
I had decided to build some shutters for the house about the time you started this thread… I had hoped for some masterful insight from the pros and have been watching this thread! I can find where others have built louver style doors etc. but haven’t found any magical methods of turning the bot loose and letting it do all the work on plantation type shutters! Oh well, looks like they the bots participation will be limited to pin holes in the stiles… I bought my pins and hinges here.
http://www.profhdwr.com/34500.htm (http://www.profhdwr.com/34500.htm)
be sure to post pictures!
SG

[johnh]

Thanks folks.

I'm still in planning stage (and still might pull out the credit card), just not sure yet.

I did come across this...

http://www.youtube.com/watch?v=Dc0rqSrbhns

At about 16 minutes into the video Norm shows why he's always gonna be THE man. Stapling jig for the louvers and control bar. Very cool.

[paul_z]

I built a vice like attachment at the end of my bot table to hold material vertically. I think it would be easy to make such a jig to hold the louvers and make the holes for the pins very accurately.

Are you cutting the louvers on the bot?

Paul Z

[steve_g]

John…
Thanks for the New Yankee Workshop link, It gave me some jigging ideas!
Paul…
How would you cut the slats on the bot?
Thanks
SG

[johnh]

Yes please, any ideas for cutting the slats very welcome. Even a different slat profile altogether that the bot (or table saw) may be more suited for. I was thinking maybe a 3/8 flat slat with a shallow rabbet along one edge might be better suited for the bot than the typical "spaceship" stretched-oval profile I have mostly seen in the store bought units. Rockler does carry a router bit to cut the oval profile but I think I'd be worried about it dulling and burning up slat material way too soon to finish the job up.

Paul, you are so right, the bot is the ultimate jig machine. A simple slat clamp at the end of the table should be able to place the pivot and operator holes exactly where you want them.

[bleeth]

Fun watching Norm again-been years.

I don't know about Paul but I would use my big router table If I wanted to make the shutters tapered.
Amana has a couple bits that can give you the taper and finish the outside edge with a bead bit. Then sanding to clean up.
Here's a couple Amana part numbers:
49550 (Handrail and table edge bit)
54121 (Ogee raised panel bit)

Others may make similar ones as well. (Like the Rockler John found)

Set-up is a bit fussy to get it smooth and safe but it is doable without a molder that way. Of course-a lot of plantations are made with flat shutters. If you haven't swung a big panel bit in a router table the first time you do it will open your eyes way wide! I have a variable speed router in it and generally run it slowed down close to shaper speed for big bits. Slowing down the router and using a softer wood like poplar or bass will keep the burning low.

[paul_z]

I probably used the wrong word. Accuracy is not nearly as important as repeatability. Any variance in the position of the pin holes will show. That's why I'd definitely use a jig to hold the slats.

Using the shopbot to make the holes is "nice". A jig on a drill press might be even better.

In any case, I'd make some parts out of scrap first. Assemble and test. Then go for the real product.

Paul Z

[paul_z]

I'd also agree with Dave. Using the bot to shape the slats is a bit like using a claw hammer to dig a hole. It can be done by the bot but should it?

Paul Z

[gene]

I made some fixed shutters for a job that i couldnt find anything that would match what was not damaged . It worked out very good . I cut the slots in the rails on the bot the rest was done with other tools .