DIY plantation shutters from scratch

Simple steps DIY plantation shutters from scratch

Preparation is Key:

Precise Measurements

Get your window measurements right! Factor in the wood thickness to avoid any discrepancies later. A laser measuring tool can be handy here.

Wood Shopping

Choose a lightweight and affordable wood for the frame and louvers. Consider poplar, basswood, or even MDF for a budget-friendly option. Remember, 20mm thickness is ideal for both strength and aesthetics.

Pre-cutting Option

Save time by getting your wood cut to size at your local DIY store. If you're comfortable with a saw, cutting it yourself is also an option. Just be sure to follow the measured lengths meticulously.

Building the Frame:

Dry Assemble

Lay out the cut pieces for the frame to visualize the final structure. This helps identify any inconsistencies before permanently joining them.

Marking Screw Positions

Use a pencil to mark the locations where screws will join the wood pieces. Ensure the screws are long enough to penetrate both pieces (e.g., 100mm nails for 63mm wood).

Drilling Pilot Holes

Before screwing, drill pilot holes slightly smaller than the screw diameter. This prevents wood splitting and ensures a cleaner finish.

Screwing and Stabilisation

Use a screwdriver or power drill to drive the screws in securely. Apply weights or clamps to hold the frame steady while screwing, especially if using soft wood.

Crafting the Louvers:

Precise Cuts

Cut the cladding to match the exact length of the short wood frames for a seamless fit. A miter saw is helpful for achieving clean, angled cuts at the ends.

Center Marking

Use a pencil to mark the center of each louver where the pivot pin will be inserted. Accuracy is crucial here!

Drilling Pivot Pin Holes

Use a drill bit matching the pivot pin size to carefully drill one-inch-deep holes at the marked centers. Be cautious not to drill through the entire louver.

Testing and Marking

Place the louvers against the frame and trace the pivot pin points lightly with a pencil. Test the first louver by inserting the pivot pin to ensure it rotates freely without hitting the top frame. Then, mark all remaining pivot pin locations along the frame, ensuring slight overlap between louvers for a gap-free closure.

Adding Functionality:

Clearance Slots

Using a craft knife or rotary tool, carve out square clearance slots in the middle of each top frame. These slots allow the tilt rods to pass through without obstruction when adjusting the louver angle.

Louver Center Marking

Mark the center of each louver again for the tilt rod connection. This is where the screw eyes will be attached.

Screw Eye Installation

Screw in screw eyes at the marked centers on each louver. Choose screw eyes with a large enough opening to easily hook onto the tilt rod later.

Painting and Assembly:

Preparation is Key

Before painting, sand the wood lightly to remove any imperfections and ensure smooth paint application. Use painter's tape to cover any areas you don't want to paint, like hinge placement points.

Choosing Paint

Opt for quick-drying satin wood paint for a durable and elegant finish. Consider mixing the paint with a small amount of water for easier application.

Applying Coats

Apply two or three thin coats of paint, allowing each coat to dry completely before applying the next. This avoids drips and ensures a smooth finish.

Final Touches

Once the paint is dry, remove the painter's tape and lightly sand between coats for a final touch of smoothness.

Tension Louvers and Tilt Rods:

Tension Louver Holes

Drill complete holes through the frames where the tension louvers will be attached. These holes need to pass through both sides of the frame to accommodate the screw mechanism.

Flat-End Screws

Screw flat-end screws into the tension louvers. These screws provide better holding power and allow for adjusting the louver tension for open-position stability.

Marking Tilt Rods

Mark the tilt rods at points aligning with the louver screw eyes. This ensures the tilt rods will connect to the louvers correctly.

Screw Eye Placement

Screw in screw eyes onto the tilt rods at the marked points. Make sure the screw eyes are open so you can easily hook them onto the louver screw eyes later.

Connecting Louvers and Rods

Open the screw eyes on the tilt rod and hook them through the closed louver screw eyes. Close the screw eyes to secure the connection.

Hinge Installation and Final Steps:

Marking Hinge Positions

Open the shutters and carefully mark the hinge locations on both the frames and the window bay walls. Ensure the hinges are aligned perfectly on both sides.

Drilling and Securing

For the frame side, drill pilot holes at the marked hinge points and screw the hinges in place using appropriate screws. On the wall side, pre-drill pilot holes with a masonry drill bit if necessary, and then use long multi-purpose screws and wall plugs for secure attachment.

Testing and Fine-Tuning

Once all hinges are installed, open and close the shutters to ensure smooth operation. Make any necessary adjustments to the hinge placement or tension if needed.

Touch-Ups and Enjoyment

Apply touch-up paint to any areas where screws or hinges might have chipped the paint. Stand back and admire your beautiful, custom-made plantation shutters!

If you looking to shop plantation shutters in Melbourne then visit our showroom get your custom factory direct shutters