How to Build Storm Shutters, Continued

• With all the machining complete, it was time to move on to assembly.

5. Assembly:

• They began by laying the shutter pieces out. Starting with the inside edges and the rabbet they had cut.

• They began assembling the shutters from the center outward.

• They slid each tongue into the corresponding groove. Ron said it was easier to assemble the shutters first and then trim them to size afterwards.

• They held the boards together by attaching strips of one by four lumber across the backs. They cut three boards, called battens, to length for each shutter.

• They attached the battens with screws that were countersunk so that the heads were below the surface.

• Ron did not want the Phillips head screws to show in a restoration project like this one but he liked to use them because they were rust resistant and held up well over time. In order to conceal the screw heads, they used wood putty.

• After the screw heads were concealed, they turned the shutters over.

6. Trim to size:

• They transferred the window measurements to the nearly completed shutters.

• Using a circular saw with a clamp on straight edge, Eric cut each shutter to length.

• Then Patrice cut each shutter to the proper width.

7. Add hinges:

Once their shutters were fully assembled, they still needed to attach hinges. Using a hammer and chisel, Eric cut mortises or rectangular recesses on the outside edges.

• The mortises would allow the hinges to be installed flush with the surface.

• These hinges were purchased at a French quarter store that carried pre-civil war era reproduction hardware for restoration projects just like this one.

8. Hang shutters:

Finally it was time to hang the shutters. Ron set shims in the windowsill to provide clearance underneath so that the shutter did not drag on the sill. They carefully set the first shutter right on the shims.

• With the shutters resting on shims, Patrice transferred the hinge location on the shutter to the window frame.