Large Shutters with the Domino?

[jujigatame]

Hi all,

How would you make a production run of large louvered slat shutters or panels?

They're going to be large shutters made out of either Azek (probably 1x4) or pressure treated pine (possibly 2x4). and each will be about 6ft high by 8 ft. wide.

They won't be hinged, they're more of a louvered panel than a shutter, but I don't know how else to describe.  My architect is sending me a rendering that I'll upload when I get it.

I can't really wrap my head around how to use the domino on an angle on the stiles to make the louvers... Besides scribing a line.  But that's not repeatable and I need repeatable as there will be at least 48 6ft high stiles (probably more if I use a center stile).

I need to figure out how to make a repeatable jig that will cut two mortises per slat on each stile at about a 45 degree angle and space them all out evenly.

Any ideas will be GREATLY appreciated.

 

[jujigatame]

Oh and the stiles will be made out of 2x4 or 2x6 lumber with the slats attached to the wide face.

 

[ChuckM]

Not sure if this is what you're going after. You need to make a cradle so you can orient your DF (assuming it's a paddle type, not the pin type which wont need a cradle to do louvers) at the desired angle and make the plunges:

[attachimg=1]

[attachimg=2]

[attachimg=5]

After --Completed in 2019 for added privacy (in place of cotton screens)                                                                        Before
[attachimg=3]                            [attachimg=4]

 

[woodferret]

Azek vs pressure timber is kind of a big difference.  You basically need to do the center panel domino trick and make a jig for that 45.  Edge referenced if it's Azek, but building lumber is a junk-shoot.  For that later case, your best bet is centerline, and a long board that has the 45 with a sight window further up to find the line.  The distance between that and a mark on the 45 angle should at least guarantee some degree of accuracy.  Gang the two stiles and mark spacing as you would studs, then line up the jig to that.

edit: ah, ChuckS has it there.  That and just longer.  And I don't think you really NEED that cartoon wall cutout shape.

 

[alltracman78]

I would think an angle iron (90* long "corner") shaped jig may work better?
The side that is flat to the cutting face has the angle of the louvers cut on the end. Reference the angle to a line for each louver.
Bottom of the Domino rests against the angle.
You can use either a pin (I only have the DF700, so not sure of the exact setup for the 500) or a stop on the angle to reference the domino side to side.

And yeah, if you're going to be using pressure treated you may want to mill it a little bit to ensure consistent dimensions.

 

[ChuckM]

Let's have a bit of fun, since there're many ways to skin a cat. I used this for another louver shutter project:

[attachimg=1]

[attachimg=2]

 

[Lincoln]

'Festo' used to make a static machine for this very job. JFA57 'Louver Groover'.

 

[guybo]

https://www.festoolownersgroup.com/festool-how-to/making-louvers-with-a-domino/msg619988/#msg619988

 

[alltracman78]

Let's have a bit of fun, since there're many ways to skin a cat. I used this for another louver shutter project:

[attachimg=1]

[attachimg=2]

That's pretty good!

'Festo' used to make a static machine for this very job. JFA57 'Louver Groover'.

Haha!

 

[jujigatame]

So, here's what I'm trying to do...

[attachimg=1]
[attachimg=2]

there's so many of them, I'm starting to think it might be a better idea to buy a full size CNC...

But I think I could do it with the Domino and a jig.

 

[alltracman78]

You're not using Dominos to connect the Aztec?

Is there a cutter that's the correct size?

Would a router (or the CNC) be better?

 

[jujigatame]

You're not using Dominos to connect the Aztec?

Is there a cutter that's the correct size?

Would a router (or the CNC) be better?

I was thinking the dominos would be better than dados, the louvers would be 18mm thick, so a 6mm cutter should be fine.

CNC might be a better option, and as an added bonus, I get to buy a CNC!

 

[luvmytoolz]

You're not using Dominos to connect the Aztec?

Is there a cutter that's the correct size?

Would a router (or the CNC) be better?

I was thinking the dominos would be better than dados, the louvers would be 18mm thick, so a 6mm cutter should be fine.

CNC might be a better option, and as an added bonus, I get to buy a CNC!

Any excuse to get a CNC is a good excuse in my book! ;-)

 

[alltracman78]

You're not using Dominos to connect the Aztec?

Is there a cutter that's the correct size?

Would a router (or the CNC) be better?

I was thinking the dominos would be better than dados, the louvers would be 18mm thick, so a 6mm cutter should be fine.

CNC might be a better option, and as an added bonus, I get to buy a CNC!

Are Dominos good outside?
Will the PVC louvers work well with them?

I'm definitely not an expert, so I defer to those with more experience.
Just wondering.

Domino would be quicker than a dado (just plunge instead of slide).

Money aside, I would think the CNC cutting 18mm mortises would be the ideal solution.

 

[Packard]

I recalled seeing a simple jig for a router for louvers.  It was similar to this:
https://www.google.com/search?q=jig...tf-8&client=firefox-b-1-m#fpstate=ive&vld=cid:256000a0,vid:mov1-1ze_UE,st:0

I don’t know which would be more efficient, the domino or this type of jig.

 

[jujigatame]

You're not using Dominos to connect the Aztec?

Is there a cutter that's the correct size?

Would a router (or the CNC) be better?

I was thinking the dominos would be better than dados, the louvers would be 18mm thick, so a 6mm cutter should be fine.

CNC might be a better option, and as an added bonus, I get to buy a CNC!

Are Dominos good outside?
Will the PVC louvers work well with them?

I'm definitely not an expert, so I defer to those with more experience.
Just wondering.

Domino would be quicker than a dado (just plunge instead of slide).

Money aside, I would think the CNC cutting 18mm mortises would be the ideal solution.

Should be fine, just need to use poly glue instead of PVA, or just domino for alignment and screws.

 

[jujigatame]

You're not using Dominos to connect the Aztec?

Is there a cutter that's the correct size?

Would a router (or the CNC) be better?

I was thinking the dominos would be better than dados, the louvers would be 18mm thick, so a 6mm cutter should be fine.

CNC might be a better option, and as an added bonus, I get to buy a CNC!

Any excuse to get a CNC is a good excuse in my book! ;-)

That's what I am starting to think...

 

[ChuckM]

I recalled seeing a simple jig for a router for louvers.  It was similar to this:
https://www.google.com/search?q=jig...tf-8&client=firefox-b-1-m#fpstate=ive&vld=cid:256000a0,vid:mov1-1ze_UE,st:0

I don’t know which would be more efficient, the domino or this type of jig.

Norm Abram made louver shutters with a router and jig in one of his NYW episodes. Everything being equal (i.e a jig made with the slot width within the capability of the DF), the Domino Joiner is far far more efficient plus far far better (excellent) dust extraction because it's just one plunge per slot, no back and forth sliding of the machine.

 

[Crazyraceguy]

In a small (single Domino per slat) window situation, I can see the jig that  [member=57948]ChuckS[/member] posted working well.
However, when you get to slats the size of those in the pictures, it will certainly require more. That is going to pose a registration/indexing problem.
In this instance, I would make a jig that uses a router and bushing. Fences/stops/reversible etc and at least the length of the longest side. It would also work with shorter sides by just adding an additional stop.