Plantation shutters WIP

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jfc
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Plantation shutters WIP

Postby jfc » Sat Oct 03, 2009 2:52 pm

After a trail run in MDF i thought i would make my self some in Iroko .


Gaurds removed for photographic reasons .

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Ive heard people saying Iroko was nasty stuff but ive never really had a problem with it untill i cut this board . Even with the extractor going i got a mouth full of the dust and had to stop the machine as i couldnt breath :shock: Masked up and on with the job .


Face and edge the boards ready for the thicknesser




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Stack of prepared Iroko




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I'm using stop mortice and tenons on these as they dont really need anything more i think . Cutting them by hand as they are only small


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One frame ready for the blades .




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Re: Plantation shutters WIP

Postby senior » Sat Oct 03, 2009 4:24 pm

You'd work quicker if you drank less tea :lol:
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Re: Plantation shutters WIP

Postby jfc » Sat Oct 03, 2009 4:48 pm

Beer at the weekends mate , i just drink it out of a tea cup ;)

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Re: Plantation shutters WIP

Postby sainty » Sat Oct 03, 2009 4:50 pm

We've just fitted a home office into a study that had these shutters. Looked really good - from a distance. When you got up close you could see that they were just ok at best. The only thing that I couldn't work out is how you fix the adjusty thing to the slatty things, these ones had staples and the only way I could see how to do it is before it is assembled - how do you do yours Jase?

Maybe if I was a bit more patient I'd find out when you do it, but I want to know now!

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Re: Plantation shutters WIP

Postby jfc » Sat Oct 03, 2009 6:32 pm

Dunno yet :D Probably use curtain eye thingies .





Next i made up a simple jig to drill the holes in the blades




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It worked a treat



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Put a chamfer on the corners to give it some detail and shadow gaps





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Mark out the uprights that are going to take the blades





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and drill them out on my Felder piller drill








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:lol: :lol: :lol:



I think i may put a round over or a chamfer on the blades to stop them looking so chunky ??




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Re: Plantation shutters WIP

Postby jonnyd » Sat Oct 03, 2009 6:36 pm

Looking good. I think rounding over the slats would be a good idea.

Cant you rotate the pics I've got neck ache looking at them :D

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edit ive seen youve sorted the pics
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Re: Plantation shutters WIP

Postby jfc » Sat Oct 03, 2009 7:34 pm

Sorry Jon , photobucket takes a while to rotate them .



I only sussed how to make plantation shutters easy while i was making this lot :oops: Its so simple when you think about it but it looks such a PITA job to do ......




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Re: Plantation shutters WIP

Postby mattty » Sat Oct 03, 2009 7:44 pm

My Felder pillar drill looks very similar :lol:

Nice looking Job J. The slats do look a little chunky, i think i would make them slightly thinner.
Cheers, Matt.

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Re: Plantation shutters WIP

Postby jfc » Sat Oct 03, 2009 7:52 pm

I dont think making them thinner is a good idea as they are only 10mm as it is , with a 5.5mm hole to hold the pin . I do agree that they look chunky and need to look thinner . I think the ones in the shop notes i looked at with Barry where shaped like a wing which made the whole job complicated but gave the thinner look .
Ill see what cutters i have tomorrow and see if i can get a chafer on them with a roundover type effect .

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Re: Plantation shutters WIP

Postby engineerone » Sat Oct 03, 2009 10:11 pm

why not finish them after drilling etc. you could chamfer them until about 10mm from the centre, and no one would notice i think.?

paul ;)

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Re: Plantation shutters WIP

Postby jfc » Sat Oct 03, 2009 10:14 pm

Thats the plan Paul

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Re: Plantation shutters WIP

Postby engineerone » Sat Oct 03, 2009 10:15 pm

yea, but a chamfer would look just as good as the aero look, but be easier (me telling you what to do :? )
and you could round over the front. that would certainly reduce any heaviness.

next you'll be making wardrobe louvred doors :lol:

paul ;)

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Re: Plantation shutters WIP

Postby jfc » Sat Oct 03, 2009 10:29 pm

Ill see what cutters i have tomorrow and see if i can get a chafer on them with a roundover type effect .

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Re: Plantation shutters WIP

Postby engineerone » Sat Oct 03, 2009 10:45 pm

i was thinking you would cut the chamfer on the saw, and then roundover, it would surely be easier?
or on the planer, you could cut the chamfer too. i think using the router for the chamfer would be more difficult.

paul ;)

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Re: Plantation shutters WIP

Postby jfc » Sat Oct 03, 2009 11:00 pm

Heres a little clue on what i was planning to use :lol:



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Re: Plantation shutters WIP

Postby jake » Sat Oct 03, 2009 11:14 pm

I'd try and get the blades down to 5/6mm, and find some slimmer pins - I'd guess that a 2mm or 3mm steel pin would be plenty. But then these are one of those things I just don't get.

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Re: Plantation shutters WIP

Postby jfc » Sat Oct 03, 2009 11:24 pm

I think making them that thin may be asking for trouble as they are in direct sunlight all the time and magnified by the glass . Making them look that thin is the key i think .

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Re: Plantation shutters WIP

Postby jake » Sat Oct 03, 2009 11:35 pm

Yeah, you're probably right. My difficulty with these is just that wood is really the wrong material for the application!

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Re: Plantation shutters WIP

Postby engineerone » Sat Oct 03, 2009 11:38 pm

wot with those horns :lol: :twisted:

i agree if the wood is too thin it will twist and even painted it would look wierd.
paul ;)

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Re: Plantation shutters WIP

Postby bloonose » Sun Oct 04, 2009 9:33 am

The work in progress in this will be really handy, try this for your editing your pictures before posting
http://www.xnview.com/en/index.html

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Re: Plantation shutters WIP

Postby jfc » Sun Oct 04, 2009 2:54 pm

Image




Image



What do you think ?

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Re: Plantation shutters WIP

Postby senior » Sun Oct 04, 2009 3:07 pm

jfc wrote:
What do you think ?


with hands like that I'd say gay or slightly camp.
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Re: Plantation shutters WIP

Postby jfc » Sun Oct 04, 2009 3:31 pm

Image




Image

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Re: Plantation shutters WIP

Postby engineerone » Sun Oct 04, 2009 4:07 pm

does look better no matter what bob says about your hands :lol: are you going to do it before or after drilling and installing the pins? i do wonder though whether you might smooth the transition between the chamfer and the flat with a slight rounding, rather like cleaning up an arris? have you found an half round?

paul ;)

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Re: Plantation shutters WIP

Postby mrspanton » Sun Oct 04, 2009 5:04 pm

I bet thats a sod to assemble.....

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Re: Plantation shutters WIP

Postby jfc » Sun Oct 04, 2009 5:38 pm

Its not to bad as the middle part just slips in so you can fit the pins on one side and then just slot the other pins in from the back as it all gets hidden by the frame .

The last moulding wasnt leaving me enough room to attach the operation bar and i was getting snipe as you can see on the test ones above so there was only one option .......




A zero clearance fence on the spindle moulder :o :o :o :shock: :shock: :? :?




I donned my biggest man nappy downed five cans of special brew and went for it ....



There was a little bit of wee :oops:





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The new profile gives me room to fix the bar and the blades drop into each other rather well




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Re: Plantation shutters WIP

Postby modernist » Sun Oct 04, 2009 5:55 pm

I think you've cracked it - v nice
Cheers

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Re: Plantation shutters WIP

Postby jfc » Tue Oct 06, 2009 7:56 pm

Done a bit more on these today . Now i am shaping the blades ive redone the drilling jig to take them shaped so i can run them off in longer lengths . Bit of a pain running a couple of hundred blades past the cutter four times :shock:
The shelf supports i am using are the round 5mm /5.5mm and the shorter 5mm part fits the 10mm thick timber that holds the blades . Doing it this way means you cant slot the fixing pins in from the back so makes assembly a pain now . I suppose you could up the blade support timber to 15mm but i dont think that will look right :?
I think Hafele sell the parts for these shutters but does anyone know the price of them ?

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Re: Plantation shutters WIP

Postby jfc » Wed Oct 07, 2009 7:13 pm

Got all the blades finished today .



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A bit of sanding and briwax and then fit them all together






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Re: Plantation shutters WIP

Postby mattty » Wed Oct 07, 2009 7:23 pm

They look very nice J. What sort of cost for a pair that size fitted? I can see them selling well.
Cheers, Matt.

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Re: Plantation shutters WIP

Postby jfc » Wed Oct 07, 2009 7:41 pm

Not sure to be honest as most of the time has been working out how to do them and milling up my own timber .If it was a job i would buy in the timber PAR . The first one took about two days but the other three took a day once i knew what i wanted to do .


Thats the point of the thread Mr C :) No one had worked out how to do them as far as i know .

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Re: Plantation shutters WIP

Postby jonnyd » Wed Oct 07, 2009 7:49 pm

looks good. How you gonna do the rod then?

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Re: Plantation shutters WIP

Postby mattty » Wed Oct 07, 2009 7:56 pm

I've just found a firm in Manchester who quote-
How much do shutters cost?
Our Seattle range retails for £175 per square metre exactly. The Phoenix range retails for £220 (painted) or £240 (stains) per metre exactly. And the Vancouver range retails for £275 per metre exactly. Solid shutters vary in price according to the style used. A shaker style panel costs less to make than a raised panel in the Victorian/Regency style. To get an exact price go to our quotation/order or call us on 0161 788 9669



Assuming there is a reasonable installation charge on top there could be some good margins in these. The prices above refer to painted MDF, parasol wood? and the most expensive quote is cedar.
Cheers, Matt.

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Re: Plantation shutters WIP

Postby jfc » Wed Oct 07, 2009 7:59 pm

I picked up some really small net curtain hooks and eyes today . I looked at staples but after all this work stapling them together just seemed crap .

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Re: Plantation shutters WIP

Postby engineerone » Wed Oct 07, 2009 8:36 pm

very nice mate, and well done for actually finishing something that has been around in your mind for about 3 years now.

i wonder if assembly might be easier if you did it rather like a newel post on a staircase, and had spacers that had half round holes at each end, and then slid up to surround the pin?? you could have them inside a rebate to secure them until glue up is finished :?

paul ;)

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Re: Plantation shutters WIP

Postby jake » Wed Oct 07, 2009 11:12 pm

They look like good plantation shutters.

I cannot for the life of me work out why anyone in our northern light climate would want to block off that much of a window even when the blades are open, but if people are going to pay you to live in the dark, fair enough, take their cash.

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Re: Plantation shutters WIP

Postby Brad Naylor » Thu Oct 08, 2009 7:24 am

I'm very impressed. I might be tempted to attempt something similar for myself.

I don't see them as a money spinner though, for a guy working alone. You'd need to charge upwards of £500 for a single small shutter.

Maybe if the profile was mass-produced and you had a team of minimum wage women doing the fiddly bits...

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Re: Plantation shutters WIP

Postby woodsmith » Thu Oct 08, 2009 7:47 am

Looking good; looks a lot of work though and I'm not sorry I bought mine :D
Keith

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Re: Plantation shutters WIP

Postby jfc » Thu Oct 08, 2009 10:24 am

It looks alot of work but its actually very easy . I'm kicking myself for not doing these years ago when they where all the rage and higher prices could be got for them . I have just waxed 44 blades and assembled two in one hour ten mins .

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Re: Plantation shutters WIP

Postby jfc » Thu Oct 08, 2009 7:25 pm

Got the operation bars on today . Ive seen grooves in the top and bottom rails on shutters and know realise you need these to make the blades close tight :roll:



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