A Festool perspective on Plantation Shutters or "(adjustable) Louvered shutters"

[festoller]

A Festool perspective on Plantation Shutters

I’ve been thinking about a interior Plantation Shutters project for quite some time now, but because of some issues I’ve never considered to actually try and build some.

Of course the missing FOG Plantation Shutters post was the main reason! That’s why I thought it might be the right time to start a post dedicated to Plantation Shutters or simply “interior wooden louvered (adjustable) shutters“.

This is what I have in mind:

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One issue is of course the choice of material, especially for the adjustable panels and the large numbers you have to make. I would prefer white shutters, so finishing is an issue as well, because of the large quantity and my lack of skills and tools for a professional white paint finish.

Probably the first search result you get is the New Yankee Workshop video on Plantation Shutters:
http://www.newyankee.com/getproduct.php?0602
but in my opinion the panels and jigs take to much time.

I’ve also found a post on Woodwork UK:
http://www.woodworkuk.co.uk/forum/viewtopic.php?f=9&t=3592
but he used Iroko (similar to Teak) and the whole project is probably a little to solid and would better serve an outdoor use.

And of course there’s the FOG post from Brice Burrell:
http://www.burrellcustomcarpentry.com/subpage25.html
but unfortunately those are fixed shutters.

For inspiration purposes I’ve collected a few professional manufacturers and dealers:

http://www.kellyhoppenshutters.com/
http://www.shutterworld.co.uk/
http://www.shuttermedic.com/
http://www.martinshutters.com/
http://www.buyplantationshutters.com/home.html

So the question is, how would one approach this from a Festool perspective. It’s certainly not a problem to make the frames with the Domino, but how would you make the panels, what material, hinges, general design, etc.?

Any comment would be greatly appreciated and I promise to document the whole process with photos as usual.

 

[RDMuller]

I have thought about doing this for some time, but really don't have much to contribute. 

I would like to complement you on how (a) You have titled this new topic (b) the excellent description of what you are trying to accomplish along with appropriate links as to where you are starting from.  I wish every topic had this much effort and thought put into it at the beginning. When completed by the members of FOG, I suspect this will be one of the best examples of what the FOG group can put together, and a good part of this will be due to your establishment of a starting point for the discussion.

I will contribute a little on finishing.  Spray finish if at all possible and spray before assembly with minor touch up afterwards.  Sanding between coats is far easier when not assembled.

 

[wubears71]

I made them using the New Yankee plans but utilized Festools where I could - i.e. Dominos instead of more traditional M&T joinery.  My intention was to do it for multiple windows, but after doing the 1st, I never bothered to do the others because the whole process was painstankely tedious and just the slightest mis-measurement threw the whole shutter off.

In regards to wood, I used basswood for all the louvers and Poplar for the frames.  I spray finished them with Target USL and 2 years later, they still look great.

Good luck in your qeust. 

 

[wubears71]

Here is a blog on another site I put together when building mine.  It may or may not help you in your build.

http://www.sawmillcreek.org/entry.php?45-Plantation-Shutters-Part-2&goto=prev

Here is the final result:

 

[kdzito]

Festoller, thanks for approaching this subject as this is one of my projects to attack after I finish out Kitchen cabinet doors.

It seems like the price for shutter is $150ish and this adds up really quick.  My wife received a quote just to do our living room and it was over $2K.  So I'd rather spend my time doing this and save the big $$$ or even if I have to buy another tool to help me accomplish this task it really can't be all the much $$$.

Your post helps my morale in approaching this project.

Kurt

 

[festoller]

Thanks for your answers guys and thanks for the compliment. And Tim that house looks like it was built around your shutters! Great work!

In my opinion the Plantation Shutters are one woodworking project almost everyone desires, but for known reasons only few actually built some. That’s why I wanted to collect FOG knowhow to simplify workflow and maybe “streamline” the whole process with our Festools. And maybe this turns into an actual Festool Plantation Shutter Manual.

And keep in mind, well made Plantation Shutters will result in greater appreciation of your Festool workshop, by spouses!

Tim I can’t figure out if the louvers are actually elliptical, because I think that’s where you spend a lot of time and effort. I would try to avoid elliptical if it’s possible. Most manufactured shutters I saw didn’t have elliptical louvers anyway, but I would assume they would have a greater dimming effect?

Anyway it’s save to say that using the Domino for the frames is the easiest task, but when it comes to the louvers I am not sure if plywood, Multiplex or even MDF would be the proper choice, especially because of wood movement due to sun and extreme and different temperature conditions.

As for the drilling of the frame maybe the LR32 would be of help, but drilling the louvers probably needs a jig anyway and I don’t have the LR 32. Plus I don’t know if there’s such a small router bit available.

This design looks rather promising, although the mechanics on the control bar could be improved and I wouldn’t install the frame directly on the window frame and instead install it like Tim did, level (flush) with the interior wall.

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I hope we can collect more good ideas and tips!

 

[wubears71]

The louvers are elliptical to minimize the light when they are closed.  Without the Elliptical design, they don't close all the way.  The most tedious part by far is hole drilling and the jig has to be very stable as small deviations in the holes results in very uneven louvers, which looks terrible when closed - the light really enhances the mistake. 

 

[festoller]

That's what I thought! And of course eliptical will be much more time consuming not to mention the drilling. I don't have a fixed drill press and it makes me wonder how to get this part done without deviations.

Basswood by the way seems to be the most favourite material for shutters. If the louvers are not eliptical I would think about basswood ply for those.

 

[fidelfs]

I have made them before using New Yankee plans and some that I found in a magazine. There is a supplier that sells the kit to do the louvers in a table router.  I amworking in New York (computer business) and I dont have the name of the supplier with me.  I will come back home over the weekend and I will post thename.

They sell the router bit,and the plasitc thingies to attach the louvres to the frame.  I think the yankee jigs are not completely necesary, and/or you can make changes.

I think you can attach your hand held drill to a base ( made or bought ) and it will do the same as the drill press.

It takes time but if you run batches it will speed up the process.

Sorry if i make typing mistakes, using my phone on my lunch hour.

 

[Ocram]

Maybe this is an idea, shutters without the Elliptical design.

They open and close whit a thin bar on the side.

http://www.styleshutters.nl/423/nieuw:_shutters_Jan_des_Bouvrie

 

[wubears71]

Maybe this is an idea, shutters without the Elliptical design.

They open and close whit a thin bar on the side.

http://www.styleshutters.nl/423/nieuw:_shutters_Jan_des_Bouvrie

Wow.  I love that design on the louvers - rabbetting would be so much simpler than making elliptical shaped louvers with a router bit.

 

[NuggyBuggy]

Tim - when you say the louvers are elliptical, do you mean in profile they are elliptical through their entire depth ? Or do you mean that in profile, they are rectangular with rounded corners  ? Because to my recollection, none of the shutters I have ever seen have been elliptical in profile, but rather rectangular with rounded corners.

Just wondering - I have always wanted to build these.

 

[wubears71]

Tim - when you say the louvers are elliptical, do you mean in profile they are elliptical through their entire depth ? Or do you mean that in profile, they are rectangular with rounded corners  ? Because to my recollection, none of the shutters I have ever seen have been elliptical in profile, but rather rectangular with rounded corners.

Just wondering - I have always wanted to build these.

Definitely NOT through the entire depth as there is a flat part.  It's basically an elongated bullnose profile on each end. 

 

[festoller]

Ocram, that looks like a great design! Although I couldn't find any detail or photo for the bar and mechanics to move the louvers. Did you inquire some more information from that company?

It seems to be a much simpler way for indoor and outdoor use.

 

[Ocram]

Hello Festoller,

I can not find any documentation on open close mechanism. But i have seen it so i made a drawing.
To open or close the shutter you just have to push on the louver. The strip on he side makes sure they all go together.

The outdoor shutters are made of aluminium.

Sorry fore my English, and i wish you good luck.

 

[Ocram]

[embarassed] I hope this works

 

[festoller]

Thanks Ocram, that’s what I thought and although the louvers are much easier to make (rabbetting instead of elliptical routing) the probably hidden mechanic that connects the louvers looks a lot more complicated than the usual bar they use on plantation shutters.

Of course maybe a more skilled FOG member than I could find a simple design to make these rabbetted louvers work?

The beauty of this design is the flat surface design you get when the louvers are closed. Also cleaning seems much easier.

These are the some photos I found, maybe someone can figure out a design for the mechanics?

Check out photo 1, these people know good tools, looks like a T15

[attachimg=1]
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[Ocram]

Check out photo 1, these people know good tools, looks like a T15

I think they can afford it, the Jan des Bouvries shutters start at 525 euro a square meter [eek]

 

[woodguy7]

This is such a cool thread.  Like everyone else, I've been planning to make a set for some time now.  I did buy cutters for my spindle moulder to make totally elliptical slats as i think they look best but i just love the clean look of the rebated ones.  I think i will make a set of these for the workshop first to see how i get on. 

Some thing i read a while ago about tensioning the slats.  Some company's replace one pin around the centre with a screw so that if the mechanism becomes too slack & the slats want to fall closed all the time, you just remove a plug & put a turn on the screw.  Because all the slats are linked they all stay open.

When i get a chance to start this i will take pics & post here but in the meantime i will be following this thread with interest.

Woodguy.

 

[festoller]

Woodguy7,

could you share your thought on how you would move and connect the louvers. Do you intend to use a control bar, or do you have an idea how to design the hidden version?