I spent the better part of the weekend getting the shutters made... they will be installed today.
I tried to do a little tutorial along the way for you interested parties that might want to replace those plastic ones... they are inexpensive and easy to make.
The hardest decision you will make is what width of board you would like...
I chose a 3.5" W x 1" T...
(TIP: have the lumber company rip these out of a 12" board which is much cheaper in the long run... measure your height and have them cross cut the boards too).
I used rough barn board so I had a lot of sanding to do... I don't suggest using this wood, next time I would spend the little extra and buy a smoother finish. I curved my edges as shown...
(TIP: put your sander on an angle and sand the edge rolling the sander back and forth, you just want to take the sharp edge off.
I left a 1/4" gap as these are going on a south wall... they will need a little breathing space for expanding and contracting. This is also a great fix if your boards don't line up perfectly.
- Clamp the boards together and measure your width for the batten.
(TIP: I used paint sticks between the boards for my gap... they will be pulled out later)
- measure 6" from the bottom and mark your line... cut and sand your batten, then use your angle square to line everything up...
- clamp the boards and batten tightly on both ends
(TIP: this is the best $20.00 you will ever spend... I have used this tool more in my workshop than any other tool).
- flip your boards over
- draw a line down the middle of the batten on the back
- drill and countersink holes...
- I used 1 1/2" screws...
- if you don't countersink holes then I suggest you use 1 5/8" screws for 1" boards
- do both ends
- remove clamps and paint sticks
there you have it... new rustic, wooden shutters
- stain boards (you can do this before or after assembly, your choice)
- I used Sherwin Williams semi-solid waterborne stain (great coverage, dries quickly and leaves a nice eggshell finish)
- affix hardware ( I found these on Ebay very CHEAP... they are just plastic but you would never know from a distance)
Now time for the installation... pictures to follow.
Hope this was helpful, if you have any questions please do not hesitate to pop me an email I will be happy to assist in any way I can.