Window Shutters
Make your own wood window shutters for a lot less...and easy too!
Supplies
plywood approximately 1/4" thick
table saw (or Skill saw)
measuring tape
piano hinge
metal snips
jeweler's saw (or Dremel)
ball pein hammer & metal block (optional)
patina (optional)
torch (optional)
drill (or drill press)
drill bits
lubricant
rivets
rivet gun
stain
Cut Your Hinges From a Continuous Hinge (Piano Hinge)
I chose to make a butterfly shape hinge from a continuous (Piano) hinge, basically cutting the existing hole out, but you can be creative and make any shape you want as long as you have enough hinge segments.
Separate the Hinge Segments by Using a Jeweler's Saw or Dremel Tool
Trim Off the Excess Using Your Snips
Planish With a Ball Pein Hammer, If You Desire
Straighten Out the Hinge by Hammering Front, Back and the Hinge Itself to Insure It Is Working Friction Free.
If You Want to 'antique' the Hinge, Put It Under a Torch, or Add a Patina Like Liver of Sulphur
Sand Some of the Patina Off With an Abrasive. I Like to Use a Scotch Bright Pad. the Patina Stays in the Recesses.
Drill Your Holes. I Made a Jig to Hold the Hinge Making It Easier on My Fingers. Use a Lubricant to Save the Life of Your Drill Bit. Then Either File Off the Excess Metal on the Backside or Hammer (faster)
Measure Your Window, Figure Out the Width and Height of Your Shutter Slats, Then Cut Using Either a Table Saw or a Skill Saw. It's Ok to Not Be Perfect As the Look of These Are Reminiscent of Barn Siding.
Measure and Mark Where You Will Be Mounting the Hinges.
This window is 69" x 69" so I cut my slats at 4 3/16" intending to have two sets of shutters that open. Start with hinges on a outside board, then skip one, etc. (...because you will be mounting hinges on the backside so that it will accordion together.)
Rivet Your Hinges by Using a Rivet Gun and the Appropriate Size Rivet. I Like to Use Aluminum Rivets As It Is Easier on the Hands, However, You Can Find Beautiful Copper and Brass Rivets.
Tip: only drill one hole at a time, secure rivet, then on to the next. This helps keep things true. Keep rivet gun butted up close to the hinge. 2 or 3 pumps will snap it off. You can also use small bolts and nuts if you wish.