Replies

1. 
   IanC | Jan 11, 2004 04:58pm | #1

   Steve,  There's a  jig in FWW#74 in the Methods of Work section for fixed louvre shutters.  For one cupola's worth, you might look into modifying some store bought (or flea market) shutters.

   Ian 

1. 
   dirtstirrer | Jan 11, 2004 05:18pm | #2

   Thanks Ian.  My FWW collection has a gap in it from about 40 to 100, so I'll have to go to plan B to see that jig.  I was thinking that this would be a good reason to build a good adaptible jig, that might be used on some shutters for the house too. Steve

1. 
   jackplane | Jan 12, 2004 05:38pm | #3

    I built a jig to make a dozen shutters once.The router rode on two blocks attached to a subplate,that allowed a fore-and aft movement (with stops) The two blocks snugly fit over the shutter stiles. This, along with your imagination, can do the job.

1. 
   dirtstirrer | Jan 12, 2004 06:00pm | #4

   There seems to be two variations on the theme, one like yours, and the type with "v" grooves for a busing to follow.  I went ahead and made a "v" groove one.  Sounds like they both work.  I wonder if there are any comercial jigs out there?  I guess CNC would work really well for this process wouldn't it.

   What angle did you set your louvers at?  aka Steve

1. 
   jackplane | Jan 12, 2004 06:10pm | #5

   Can't remember the angle,I measured from an original.

   CNC is a whole different kettle of fish,but if you had about 100 or more cupolas to do, they'd be the ticket.

2. 
   Steinmetz | Jan 13, 2004 08:25am | #6

   Steve, so long as your cupola is up on the roof,you dont need any special joinery or jig, if you know how to make finger joints on the table saw.

   Using your miter gauge, just cut through slots equally spaced at the correct angle and wide enough for your stock 1/2" Would be fine. The slats can be made with two 'Ears'and one rounded face edge.(Exterior) and slid into the assembled frame

   When all is in line and ready, tack a few galvanized pins to each ear to hold the slats in place

      Use oil based exterior paint before assembly.(Primer and two coats)  Stein

1. 
   dirtstirrer | Jan 13, 2004 08:52am | #7

   Hey Stein,

   Two problems.  One, I didn't want through dados for the louver slots.  I guess a router table and a stop block, while using the miter gauge would have done it.  Second, and the reason for wanting to use a stop dado instead of through, the gazebo is finished with Penofin rather then paint, so the joinery really stands out. 

   It's my most involved project to date and sits where there is a lot of foot trafic beside a old folks home.  Might draw a customer or two I'm hoping.

   I just glued the side panels together for the cupola, tomorrow night, its roof.

   aka Steve

1. 
   Jamie_Buxton | Jan 14, 2004 12:31am | #11

   If you have a hollow-chisel mortiser, there's a slick scheme that is lots less work than the router jig, particularly if you are setting out to cut stopped mortises with your router.

   Set the chisel so that it is perhaps 45 degrees to the mortiser's fence.   March down the stiles cutting square mortises.  Leave square tenons on the ends of the slats -- you can do it on a table saw, and can even gang-cut them if you like.   Pop the slats' tenons into those square mortises, and you're done.

   Okay, maybe you don't like your slats at 45 degrees.   Just set your desired angle on the mortiser's chisel.

1. 
   dirtstirrer | Jan 14, 2004 03:10am | #13

   Ah ha, another reason to get a hollow chisel mortiser!  Sounds like a slick method.  A bunch faster then the router jig I took all morning to make. aka Steve

3. 
   hmthomas | Jan 13, 2004 04:47pm | #8

   I too saw Norm build the shutters with a shop built jig but it was awhile ago and I can't recall exactly how he did it.  I think I saw it in his teak bar project but its been bugging me so I went to the New Yankee site in hopes of seeing something that would clear some of the sawdust in my recollection center. I found that you can buy plans for the jig there. They won't show you the jig but plans are available.

   Hopefully somebody will recall how he made it.

   Good Luck, Hugh

1. 
   dirtstirrer | Jan 13, 2004 05:53pm | #9

   I coudn't remember which project it was on, but I think you're right.  They don't give anything away on his site do they.aka Steve

2. 
   JDorn | Jan 13, 2004 06:29pm | #10

   There was a shop jigs episode a few months ago where he talks about building that jig for those shutters.

4. 
   Tao | Jan 14, 2004 02:06am | #12

   I've taken a few old (pre-1900) exterior louvers apart, and the stiles were made like a  sandwich.  The center strip had through cuts like diagaonal finger joints as suggested above, and there were two facing strips glued onto the front and back.  Quick, easy, good looking.  It's the way I would do just one.  I'd have 8 stiles made while anybody else was making a jig, I think.

   Michael R

1. 
   dirtstirrer | Jan 14, 2004 03:15am | #14

   Those oldtimers were clever.  I think I'll use that method next time I feel the urge to do louvers.  Simple is good.aka Steve