Shutter Jig Instructions - Rockler.com

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Shutter Jig Instructions - Rockler.com

1 1 ⁄4" Fixed Louver

Shutter Instructions

Congratulations on your purchase of the 1 1 ⁄4" Fixed Louver Template Set! These instructions will guide you

through the process of building a Traditional Shutter. Familiarity with the instructions will make the process

easier to understand and more enjoyable.


1

Inside mount no frame

• Window opening should

be nearly square

• Solid wood jamb needed

• Butt hinge application

Fig. 1

Fig. 2

Fig. 3

Mounting

Considerations

Inside mount

hang strip

Wall with or without trim

• Mounting for window openings

that are not square

• Hang strip may need to be

mounted towards the room

• Wrap around hinge application

Outside mount

hang strip

• Recommended for

drywall openings

• Mounted flush

with hang strip

• Butt hinge

application

Wall with or without trim

1 3 ⁄16"

1 1 ⁄16"

13 ⁄16" Min. Depth

Requirement

Hang

strip

11 ⁄16" Min. Depth

Requirement

1 1 ⁄16"

Hang strip

1 3 ⁄16"

1 1 ⁄16"

1 1 ⁄16"

2 3 ⁄16"

2 1 ⁄8"

Stile

Stile

2 3 ⁄16"

Stile

1 1 ⁄16"

Window

Window

Window

Rail

Rail

Rail


Use caution when

clamping softwoods

1 1 ⁄2" Stile

Bottom Rail

2" min.

5" max

Shutter Mounting and Measuring

1. Determine mounting applications and prepare

windows. Fig 1, 2 and 3.

2. Once window prep has been completed,

determine the number of shutters desired

per window.

3. Measure for panel height. For inside mount panel

height measure the total window opening and

subtract 1/4". For outside window mount,

measure the total window opening and add the

desired top and bottom overlap.

4. Measure for panel width by dividing the total

window opening by the number of shutter panels

and then subtract the appropriate gaps.

Note: Leave 1/16" gaps where hinges are

mounted and 1/8" gaps between panels.

5. Take these measurements and plug them into

the Shutter Design Wizard at rockler.com to

Top Rail

2" min.

5" max

1" between

louvers

1 1 ⁄2" Stile

create your Bill of Materials and Dimensioned

Plans specific to your shutters.

Shutter Design Options

1. A Middle Rail is recommended

for shutters over 48" in height.

Remove 2 or 3 Louvers from the

shutter and replace with a 2" or

3" wide rail with 3/16" rabbets

on both sides.

Stile Stile

1 1 ⁄2"

1 1 ⁄2"

Mid

Rail

2. Consider rabbeted stiles between

panels to block light transmission. Add 3/8"

width to one stile to create the overlap.

2


3

PARTS LIST - 1 1 ⁄4" FIxed LOUVeR TeMPLATe SeT

1

Quantity

1 Stile Jig 1

2 Router Guide Bushing 1

2


Left

Stile

Right

Stile

Fig. 4 Fig. 5

Routing Stiles

1. Place shutter frame components face side

down on work surface.

2. Label back side of stiles and rails.

3. Measure the width of the top rail and transfer

that measurement to the top end of each stile.

Measure the width of the bottom rail and

transfer that measurement to the bottom

end of each stile.

4. Clamp stiles to Stile Jig (1), aligning the top

rail mark with the etched line that says “Align

with Top Rail” on jig template.

Note: Be sure that the stile faces are towards

the Jig fence back sides out. Fig. 4.

5. Install the 3/8" Router Guide Bushing (2) and

a 1/4" mortising bit into your router. Set depth

to 5/8". Fig. 5.

6. Rout your stiles. Move stiles along jig to

complete desired series of holes. Fig. 6.

Fig. 6

4


3

Shutter Assembly

1. Depending on selected finish (paint, stain

and/or clearcoat), prefinish components

before assembly

2. Stand the right side stile on the work

bench, mortises up.

3. Insert all of the louvers vertically into the

stile. Do not apply glue to the louvers. Fig. 7.

4. Apply glue to the dowels and insert the top

and bottom rail into the stile.

5. Apply glue to the exposed dowels in the top

and bottom rails. Do not apply glue to

the louvers.

6. Working from top to bottom of the shutter

align the louvers into the appropriate mortise.

Move down the stile until all louvers are

seated. Fig. 8.

7. When all parts are together, clamp the

frame tight and check for square.

Fig. 8

Fig. 7

Mortised

Slot

Louver

Stile

Attention Rockler Plan User

Before starting, please read the plan completely. Check

Rockler.com for updates that may not be included on this copy.

If you have further questions, please contact our Technical

Support Department, 1-800-260-9663 or support@rockler.com


Notes

4


49470

Rev 03/12

Distributed by Rockler Companies, Inc.

©2012 Rockler Woodworking and Hardware

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