Wooden Shutter Repair

Tools:

safety glasses and dust mask
drill and bits
combination square
pencil
table saw
file
tenoning jig
miter gauge
rip fence
push sticks
band saw
table or workbench
drill with collar
hammer
chisel
spring clamps
hexagon wrench
woodworking clamps
rubber mallet
hand saw
scrap wood
dowel
wood glue

1. Remove rail by drilling out the pin that holds the mortise and tenon together.

2. Use a combination square to measure the size of the tenon and depth of cuts you'll need to make to craft a replacement (figure A).

3. Transfer measurements to the blank piece of lumber you're using as a replacement (figure B). Take measurements for the shoulders and transfer to the blank as well

4. Make notations on the blank as to what each of your markings represent.

5. Set wood in tenoning jig on table saw and begin cutting away for the new style (figure C). Be sure to wear safety glasses and a dust mask while working with power tools.

6. Clamp the piece into a miter gauge, set the table saw blade to the correct height and cut out shoulders (figure D).

7. Hold both pieces side-by-side and mark contours for your shoulder cut (figure E). Use the combination square to gauge the depth of the haunch and to also mark any longitudinal grooves.

8. Rip the board to the correct width using the table saw. Be sure to use push tools and keep your hands well away from the blade.

9. Cut the contours and haunch using a band saw (figure F). Use a hammer and chisel to chop out divots at the base of the tenon's haunches. Smooth the surfaces with a file.

10. Mark the new piece for the center slot. Carve out slot using a half-inch drill bit followed by some work with the chisel.

11. If necessary, round off pegs of replacement slats with an old bicycle hexagon wrench (figure G).

12. Put in new slats and bottom rail or style. Use a block of wood and a rubber mallet to knock things into shape (figure H).

13. Drill new holes for dowel pins, coat pins with glue and insert in holes. Cut pins off so they're flush.