First, all parts are cut to length according to the exact specifications for your custom shutter. After parts are cut, they are placed onto a cart with job sheets that details each opening in the order.
At Kirtz we take a few extra steps during assembly before the panel comes together to make sure that your shutter is built to the highest of quality standards.
Each tilt rod is given personal attention. We shape the top of the tilt rod in a machine we designed to give the rounded top that is unique to a Kirtz Shutter. Then, the top of each rod is sanded smooth so it has the same quality finished look as other parts of our shutters.
After shaping it is sanded smooth
Before the shutter is put together, each louver end is burnished with a sander. Again, this extra step allows the ends of the louvers to accept the painted finish better, and eliminates the rough ends you would typically find with louvers that are cut, but not sanded.
Burnishing louver ends
Next, the louvers and tilt rod are fed through a machine that attaches them together with staples and puts pins in the end of each louver, and your shutter panel is ready to be put together.
Joinery of a Kirtz Shutter
At Kirtz we use dowels to join the stiles and rails of each shutter together. Wood glue is put into each hole that will be receiving a dowel. Then we use dowels that are slightly larger than the hole they are inserted into. This requires the use of a hydraulic clamp to put the stiles and rails together. After the shutter has been clamped together, small pin nails are applied to the backside of the shutter through the dowels, giving it an extra dose of reinforcement.
This method has been used by Kirtz for many years, and we confidently stand behind the joinery of a Kirtz Shutter for a lifetime.
The shutter comes together on the clamp table and is pin nailed for extra strength
Framing
Just like a door hangs in a frame, many times your hardwood shutter will be in a frame. We have several framing options at Kirtz to accommodate a variety of decors and types of windows. After your shutters have been assembled, the frames that surround them are built.
At Kirtz we customize many of our frames so that they fit around window cranks and lever locks. By doing these notches in the factory when possible, the notch receives a finish coat of paint instead of touch up in the field.
For more information on notches, see my post about plantation shutters in casement windows.
This completes your shutter assembly, next stop finish department!
Tags: casement window with shutters, construction of shutters, custom shutters, how to choose the best shutter, plantation shutters, quality custom shutters, window cranks and shutters
Hi Heather,
You mention that you are putting wood glue INTO the drilled hole (rather than lathering it on the dowel itself). What happens to the excess glue?
When glue is applied to the dowel, the process of inserting the dowel forces the excess glue out. However, we’ve found that if you put the glue in the hole and THEN install the dowel, excess glue gets compressed at the bottom of the hole. Over time, hydraulic pressure causes the glue to expand and start pushing the stiles apart.
Have you had the problem?
Stephen Wade
Stephen,
We do put the glue inside the hole, and also apply some to the dowel itself. We have been doing it this way for many years and have not had an problems with the joints pulling apart. Maybe we use a smaller arount of glue that you guys were using, or the extra reinforcement of the pin nails through the backside keeps any potential expansion in check. And customers can rest assured our shutters are warrantied for a lifetime, so if a customer did experience any problems we would take care of it.