Need to build a replacement shutter... got any advice?

[Kevin Stricker]

Cedar for the frame and MDO for the panels.  Maybe not as durable as Azec but more dimensionally stable and plenty durable.  Oil based primer on all surfaces not glued, with 5mm Sipo dominos, exterior rated pocket screws and TBIII for the frame.

I have re-milled 25 year old cedar decking into perfectly functional and beautiful hand rails.  Wood quality is not as good these days but you can still find some great heartwood if you are selective at the lumber yard.

 

[Electric Trim]

Brice,

I don't think that your suggestion has gotten this off course at all.  Material choices are what were asked for, and you supplied a very viable material.  Color choices and products and warranties are all part of the equation.

Peter

Definitely agree Brice.  I'm not really ruling anything out.  Thanks for the input.

 

[Nigel]

    I've just made some replacement shutters like this.They are 3m in total width with 3 leafs each side.The originals were all oak.I'm not kidding when I say they weighed a ton.They were also all very warped.
Well I needed lightweight so I used pine frames with exterior ply panels.The frames are double haunched morticed and tenonned.I'll know if it's right in year or two!

 

[tiralie]

What kind of materials would you guys use on this?

My first thought for heavily exposed areas is always cedar. Western red cedar seems to be the preference in the US. It holds paint well (if the moisture level is correct)  and it a joy to mill. It's a little soft for heavily trafficked fixtures like gates etc. but I still like it.
Folks here (North East) use MDO for exterior, but the construction is not true rail and stile but an applied rail and stile design where the rails and styles are over laid, glued and pinned to a large panel creating a rail and panel look. The edges are usually covered with a poplar molding and then primed.
Pine (ponderosa)  is also used in exterior applications here, I am not a big fan of it but some of the window makers use it.
Heart pine (reclaimed) maybe another alternative. It is almost as  hard as Red oak.

I'm thinking mahogany for the outside but I'm unsure about the flat panel.

I think mahogany is a bit of overkill but I can see why you would use it. Unless this is going to be a clear finish and you can see the wood it just seems unnecessary though. There was a good discussion about choice of wood, construction techniques etc. for an  Arched Gate on Wood web.

The new one will be painted the same.  Any thoughts?  Money isn't a problem for this customer.

Money is always an issue  [big grin]
I think the paint (color and adhesion) because of UV will be the number one issue here particularly on a south facing (in direct sunlight) wall.
Folks recommend Sikkens Cetol system for this situation although I have never used it so I can't recommend it. It looks like this shutter is failing due more to lack of maintenance than any thing else, so you may want to include a maintenance schedule (option) in your pricing.

Also, any pointers on how to construct it are welcome.

Depending on what material you use I (mdo, PVC solid wood) I would favor mortise and tenon of which you have had plenty of great advice already. I think you do need to think about the drainage on the bottom rails if your profile is at right angles to the face.

Tim

 

[Brice Burrell]

Okay, I talked with my Azek rep and he confirmed what I remembered from a conversation with another rep several years ago.  Azek can be painted dark colors (even black) with Sherwin-Williams VinylSafe paint and they will honor the warranty.