4. Apply construction adhesive and lay up horizontal boards. Next take your construction adhesive and apply it to the vertical boards where your cross members will go.
Now it’s time to place the horizontal boards. Here is where your spacers come in. Make sure you slide the boards down tight to the spacers and keep the vertical boards tight and square to the jig. Once the cross members are in place and square, tack them with a pneumatic nail gun.
Make sure you don’t shoot the nail out of the back side of the board! By using a finish nail you should only have a small mark left that will be covered by the final paint job.
I recommend stacking all the shutters on a flat surface and applying weight to the top of the stack. Let them sit overnight for the construction adhesive to fully cure.
5. Complete the finish paint coat. Now that the construction is finished it’s time to give them the final paint job. We painted a few manually and also sprayed a few. If you have a sprayer, that’s the easy way to go, but it’s not needed. Depending on your quantity of shutters, it may be more hassle than it’s worth to use a sprayer.
The trickiest part to manual painting was getting into the gaps. We ended up using a sponge brush to get down in the seam. In retrospect, I should have probably rolled the board edges prior to assembly.
Once the gaps were painted, we rolled the flat surfaces. We applied 2 coats to the front and rear of the shutters.
Below are the finished shutters drying in the sun. Notice that we created several different sizes for different windows, all using the same jig.