Window Shutters

Make your own wood window shutters for a lot less...and easy too!

Supplies

plywood approximately 1/4" thick

table saw (or Skill saw)

measuring tape

piano hinge

metal snips

jeweler's saw (or Dremel)

ball pein hammer & metal block (optional)

patina (optional)

torch (optional)

drill (or drill press)

drill bits

lubricant

rivets

rivet gun

stain

Cut Your Hinges From a Continuous Hinge (Piano Hinge)

I chose to make a butterfly shape hinge from a continuous (Piano) hinge, basically cutting the existing hole out, but you can be creative and make any shape you want as long as you have enough hinge segments.

Separate the Hinge Segments by Using a Jeweler's Saw or Dremel Tool

Trim Off the Excess Using Your Snips

Planish With a Ball Pein Hammer, If You Desire

Straighten Out the Hinge by Hammering Front, Back and the Hinge Itself to Insure It Is Working Friction Free.

If You Want to 'antique' the Hinge, Put It Under a Torch, or Add a Patina Like Liver of Sulphur

Sand Some of the Patina Off With an Abrasive. I Like to Use a Scotch Bright Pad. the Patina Stays in the Recesses.

Drill Your Holes. I Made a Jig to Hold the Hinge Making It Easier on My Fingers. Use a Lubricant to Save the Life of Your Drill Bit. Then Either File Off the Excess Metal on the Backside or Hammer (faster)

Measure Your Window, Figure Out the Width and Height of Your Shutter Slats, Then Cut Using Either a Table Saw or a Skill Saw. It's Ok to Not Be Perfect As the Look of These Are Reminiscent of Barn Siding.

Measure and Mark Where You Will Be Mounting the Hinges.

This window is 69" x 69" so I cut my slats at 4 3/16" intending to have two sets of shutters that open. Start with hinges on a outside board, then skip one, etc. (...because you will be mounting hinges on the backside so that it will accordion together.)

Rivet Your Hinges by Using a Rivet Gun and the Appropriate Size Rivet. I Like to Use Aluminum Rivets As It Is Easier on the Hands, However, You Can Find Beautiful Copper and Brass Rivets.

Tip: only drill one hole at a time, secure rivet, then on to the next. This helps keep things true. Keep rivet gun butted up close to the hinge. 2 or 3 pumps will snap it off. You can also use small bolts and nuts if you wish.

Window Shutters

Window Shutters

Supplies

Cut Your Hinges From a Continuous Hinge (Piano Hinge)

Separate the Hinge Segments by Using a Jeweler's Saw or Dremel Tool

Trim Off the Excess Using Your Snips

Planish With a Ball Pein Hammer, If You Desire

Straighten Out the Hinge by Hammering Front, Back and the Hinge Itself to Insure It Is Working Friction Free.

If You Want to 'antique' the Hinge, Put It Under a Torch, or Add a Patina Like Liver of Sulphur

Sand Some of the Patina Off With an Abrasive. I Like to Use a Scotch Bright Pad. the Patina Stays in the Recesses.

Drill Your Holes. I Made a Jig to Hold the Hinge Making It Easier on My Fingers. Use a Lubricant to Save the Life of Your Drill Bit. Then Either File Off the Excess Metal on the Backside or Hammer (faster)

Measure Your Window, Figure Out the Width and Height of Your Shutter Slats, Then Cut Using Either a Table Saw or a Skill Saw. It's Ok to Not Be Perfect As the Look of These Are Reminiscent of Barn Siding.

Measure and Mark Where You Will Be Mounting the Hinges.

Rivet Your Hinges by Using a Rivet Gun and the Appropriate Size Rivet. I Like to Use Aluminum Rivets As It Is Easier on the Hands, However, You Can Find Beautiful Copper and Brass Rivets.

Be Creative! Use Your Imagination...here Is an Example of Different Looks. Enjoy!