As long as you have a sub-fence on your router table and featherboards to hold the stock in place, it’s simple to produce beautiful, clean 2-13/16" molding.

The 1-1/4" diameter, 3" tall bit features a top bearing for easy reference during the final pass, as well as a sturdy 1/2" steel shank.

Create Your Own Customized Shutters

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» 3½" Shutter Measuring and Mounting Instructions

Shutter Mounting and Measuring

2. Once window prep has been completed, determine the number of shutters desired per window.

3. Measure the panel height. For inside mount panel height, measure the total window opening and subtract ¼. For outside window mount, measure the total window opening and add the desired top and bottom overlap.

4. Measure for panel width by dividing the total window opening by the number of shutter panels and then subtract the appropriate gaps.

Note: Leave 1/16" gaps where hinges are mounted and 1/8" gaps between panels.

5. Take the measurements and plug them into the Shutter Design Wizard at rockler.com to create your Bill of Materials and Dimensioned Plans specific to your shutters.

6. Cut and shape frame components to size following the custom shutter plan. Don't forget the rabbets and mouse hole. Use a 3/8" or 1/2" dowling jig for frame joinery.

If an Optional Middle Rail (not shown) is desired, remove one Louver from the shutter and replace with a 3" wide rail with 5/16" rabbets on both sides. If you are making movable shutters, an additional mouse hole will be needed, and each panel will contain two control arms.

» Mounting Configurations

» Basswood Traditional or Plantation Shutter Slats

Available in three widths and two lengths
» Traditional: 1/4" thick x 1-1/4" wide x 16" or 58" lengths
» Plantation: 3/8" thick x 2-1/2" or 3-1/2" wide x 16" or 58" lengths

All stock comes ready to paint, stain, or clear coat. Ideal for fixed or movable traditional or plantation style shutters.

» Plantation Shutter Plans

Let's face it, making a louvered shutter or door can be a complicated and tedious task. Just imagine fitting 25 or more little louvers into dadoes or rabbets! Painstaking. However, this plan provides a neat alternative idea on how to mass produce shutters like the ones pictured here production line style by using only a table saw or router.

The plan provides a jig idea, an explanation of the process, some photos to aid understanding, a few bonus tips about outdoor maintenence, and several designs which will show you how to build any size shutter or door for any application. Skill level is intermediate, but the process is easy enough to understand. Once you get a jig set up, it's smooth sailing.