Closeup of the Shutter Sunburst with operable 3 1/2" louvers.
The Sunburst installed over a framed pair of interior shutters.
I used a plunge router and a jig to cut the MDF strips used in the outer arch.
The 1/8" wood strips and MDF with a heavy amount of wood glue, prior to clamping.
Clamping the 1 1/2" x 2" outer arch together.
Using the planer to get the surfaces level, finished up with the air sander.
Marking the outer arch at 3 centers to accommodate the 3 1/2" louvers.
Establishing the angle and alignment of the louver between the outer arch and the inner hub of the Sunburst.
Using the drill press to drill the 1/4" louver pin holes in the outer arch
Drilling the 1/4" louver pin holes in the center hub of the Shutter Sunburst.
Layout lines for cutting the angles and setting the size of the individual louvers
Shop made taper jig for cutting both sides of the louvers
Lee Suber fitting the louvers into the Sunburst. Many will require a trip over to the belt sander and the bandsaw too.
Lee Suber finishing up the fitting and assembly part. Last chance for adjustments prior to being primed and painted.
The assembled Sunburst will be checked against the template and dimensions for size adjustments if needed. Priming will require taking it apart one more time.
