One of the more recent projects we finished up from our
– 3/4” plywood
– 1/4” plywood
– table saw
– 2” utility hinges
– wood glue
– nail gun and nails
– paint (or stain)
Measure the opening of the window between the trim or the window jamb, depending on where you will be attaching the shutters.
From that number subtract the thickness of 4 hinges and another 1/16” for a gap where the shutters meet.
Divide the number you are left with by 4, this is the width of each of the shutters.
Measure from the sill or bottom of the window up to the top of the center rail, where the upper and lower window meet. Subtract the amount you want for a gap at the bottom.
Cut your 3/4” plywood into 4 pieces the size of these two measurements .
Determine how wide you want your trim pieces that frame the shutter to be, we made ours 1-1/2”.
Cut strips of this width from the 1/4” plywood, enough to go around the perimeter of each shutter.
Cut 8 pieces the length of the shutter. To figure the pieces that fit between lay two strips together flush with the edge of the shutter and then measure from the opposite edge of the shutter to the edge of the strip. Cut 8 pieces at this length.
Spread glue on the back of each strip and place on the shutter even with the edge, you can nail them as you go. When you have all of the shutters done, stack them face down on a flat surface and place weight on top of the stack and allow to dry.
Sand and paint the shutters.
Attach the hinges to the shutters which will attach to the window with the barrel of the hinge facing the front. (Pre-drill the screw holes for hinges on shutters and window trim or jamb). Attach the hinges to the other side of this shutter with the barrel of the hinge facing the back of the shutter, attach the other shutter to this hinge.
Attach one of the shutters to the window making sure to keep the gap at the bottom. Hold the other shutter in position to determine the attachment point to the window which may not be the same as the other side if your window is not perfectly square. Attach shutter to window.