Remaking new shutters could almost be a full time occupation for me.
I have made dozens of pairs to replace old decaying originals such as these you can see here.
It seems that insurance companies in this region of France insist that shutters are fitted and used for added security.
Most homes and buildings in the region are fitted with them and the extremes of weather experienced here soon takes it toll.
Serving a double purpose, shutters act as a defence against unwanted intruders and also protect the interior from the weather conditions.
As usual it is not such a simple and straightforward process
remaking them as there are many factors to consider, a prime example being the one's featured in these photos which are pretty old and certainly due an overhaul.
This photo obviously, is the finished replacements made to the same measurements (as far as could be determined that is )!, using the original fittings.
This is where in fact all or most of the problems arise, many of the fittings are original and therefore made by the local blacksmiths.
With this particular set of shutters the hinge arms were handmade and so were the bolts which had a recess cut into the heads meaning I needed a specific spanner to tighten them !. Needless to say I had to improvise with this little problem.
I purchased 'Lame a volet', timber which is already seasoned and machined with a tongue and groove and bevelled edges, specifically for shutters, which in French are called Volets.
In order to give lateral strength and to stop the structure from warping, I build a sill into the top and bottom of each shutter, this has the added value of protecting any end grain from the weather.
Because the tops of these shutters were arched I made a simple template so that I could rout an angled tenon which I then fixed with glue and pegs.
Here you can see the sill ready to be fitted, complete with peg holes which are slightly offset to pull the joint together when glued I make the sill oversized and cut off the horns afterwards and trim to size.
The top is cut with a jigsaw and shaped, again I made a simple jig to ensure all tops were exactly the right shape.
Finally a good clean up is required and treatment coat applied and plenty of coats of paint/stain before the fitting. With these shutters the originals had overtime broken out of their holding stone quoins which had to bee cut out and replaced with new.
As this process is not yet complete I will insert a photo of the new shutters in place soon.
Recent Comments