These cute shutters were made to replace a pair that a client found. She found four of them that were rotted out pretty bad but she figured that maybe she could get two good ones out of the four. So she called me and I said, “Sure no problem!” I selected the two that were in the best shape structurally and removed the debris. Now to get the parts from the other two that were rotten. When I removed one of the styles that I planned on using as a replacement out pops a good three dozen carpenter ants. They scattered all over the place. So I had to empty out a good portion of the materials I had on one wall of my shop and spray and kill them all! Carpenter ants, the bane of my existence! After a good cleaning I called the client and advised her not to put them on her house and I could make a duplicate pair since she liked the marine motif so much.
The shutters measure 55″ x 18 1/8″ x 1 1/8″ thick. The joinery I simplified by making everything 5/8″ x 5/8″ meaning the dado was 5/8″ deep and 5/8″ wide. As well as a corresponding tenon. The lumber is treated as well as an exterior grade plywood. This is the first time I have used Gorilla Glue’s version of a 100% Waterproof glue. I have seen Norm Abram use it to make exterior trellises, everybody trusts that guy!
Its a polyurethane based glue and the manufacturer suggests that you wet the work piece before you apply the glue. Once the glue sets it tends to ooze out like spray foam. I had to work fairly quickly assembling the parts because the glue doesn’t give you a lot of open time to assemble. It bonded really well though and sands real easy. Cleans up well with mineral spirits.