Steps // How to Make Board-and-Batten Shutters
1 ×

Overview for How-to Make Board-and-Batten Shutters

 
Step One // How to Make Board-and-Batten Shutters

Overview for How-to Make Board-and-Batten Shutters

annotated illustration of the anatomy of a board-and-batten shutter to help you build them
Illustration by Gregory Nemec

Cut List for Board-and-Batten Shutters
For a pair of shutters to fit a window opening 36¾ inches wide by 48½ inches high:

½x6 vertical boards: eight @ 40 inches

½x6 battens: four @ 18 inches

Download the cut-list for the shutters and cut-out templates.

 
2 ×

Measure

 
Step Two // How to Make Board-and-Batten Shutters

Measure

image of a standard double hung wood window showing where to take height and width measurements to make board and batten shutters

For working shutters, to find the width of each one, measure between the window's side casings, divide by 2, and subtract ½ inch for clearance. Then, to find the width of the boards, subtract ⅛ inch for each gap and divide by the number of boards—four in our case. To find the shutter's height, measure between the head casing and sill and subtract ½ inch for clearance.

 
3 ×

Cut the Pieces

 
Step Three // How to Make Board-and-Batten Shutters

Cut the Pieces

illustration about cutting the various pieces needed to make board and batten shutters
Illustration by Gregory Nemec

If necessary, rip the boards to width using a circular saw or a table saw. Rip the batten stock to the same width, then rip 45-degree bevels into the long edges of one face. Cut the boards and battens to length.

 
4 ×

Make the Dadoes

 
Step Four // How to Make Board-and-Batten Shutters

Make the Dadoes

illustration about making the dadoes in order to build board and batten shutters
Illustration by Gregory Nemec

Clamp the boards edge to edge and use a straightedge to mark the batten locations, top and bottom. Set the saw-blade depth to ⅛ inch, and make repeated crosscuts between the marks. Use a chisel and mallet to smooth the bottoms of the dadoes.

 
5 ×

Make the Cutout

 
Step Five // How to Make Board-and-Batten Shutters

Make the Cutout

illustration showing a cut out in order to build board and batten shutters
Illustration by Gregory Nemec

Cut out your template, and make sure its widest point extends only a little more than halfway into a board. Resize the pattern with a photocopier if necessary. Dry-assemble the shutter facedown on a table, using 16d nails to maintain the gaps between boards. Clamp everything together, center the template over the middle gap, and trace its design onto the two middle boards. Now disassemble the shutter, and use a jigsaw to cut out the shape. Sand the cut edges smooth.

 
6 ×

Assemble

 
Step Six // How to Make Board-and-Batten Shutters

Assemble

illustration showing how to assemble your board and batten shutters
Illustration by Gregory Nemec

Place the battens bevel-down. Apply waterproof wood glue to the dadoes of the outside boards (no cutout) and fit them on the battens, flush at the ends. Drive two staggered 1⅝-inch stainless-steel trim-head screws through the back of the boards and into the battens. Fasten the center boards the same way, with gaps on both sides. Build the matching shutter the same way. To learn how to hang them on your house, go to saboteamos.info/jul2015.

 
7 ×

Or Buy It: The Basic Model

 
Step Seven // How to Make Board-and-Batten Shutters

Or Buy It: The Basic Model

photo of a single, wood-texture, cast foam board and batten shutter
Photo by Wendell T. Webber

The tougher the material, the higher the price per pair.

The Basic
Lightweight cast foam has a weathered-wood texture. You apply the stain and protective topcoat.

About $147 for a pair of 18-by-40-inch shutters;

 
8 ×

Or Buy It: The Mid-Range Model

 
Step Eight // How to Make Board-and-Batten Shutters

Or Buy It: The Mid-Range Model

photo of a single, western red cedar, natural grain board and batten shutter
Photo by Wendell T. Webber

Western red cedar shows off its fine, natural grain when treated regularly with a deck oil.

About $326;

 
9 ×

Or Buy It: The Luxury Model

 
Step Nine // How to Make Board-and-Batten Shutters

Or Buy It: The Luxury Model

photo of a single, solid African mahogany, natural grain board and batten shutter
Photo by Wendell T. Webber

Solid African mahogany takes paint wonderfully and is three times harder than western red cedar.

About $511;

 
 

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