DIY Network

Victorian Porch-Repair: Restoring Wood Shutters From "Restoration Realities" episode DRTR-105

	The historic district of Wilmington, NC -- where Restoration Realities helps with repairs to the porch of an 1885 Victorian.

In this episode, DIY's Restoration Realities travels to Wilmington, NC to undertake some repairs on the porch of an 1885 Victorian home. In this third segment, Restoration Realities host Bill Click assists homeowner Karan Witt in restoring damaged shutters and to re-installing them with specialized shutter hardware.

For shutter repair
Airless paint sprayer
Disc sander
Belt sander
Paint scrapers
Extension ladders
Cordless drill with pilot bits and screwdriver bits
Pliers (to remove brads and install wire staples)
Oil-based primer
Gloss or semi-gloss paint
Paintbrushes
Rags
Polyurethane glue
Wood filler
Sandpaper (assorted grits, 40 - 220)
Utility knife
Shutter hardware
For porch brackets
8-quarter poplar stock
MDF (medium-density fiberboard) for template
Drafting paper
Band saw
Scroll saw
Drill press; sanding bit
Finish-nail gun
Clamps
Polyurethane glue
Silicon caulk
Rasp
Compass
Straight-edge
Pencils

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Replacing Damaged Shutter Louvers

• Replacement louvers (figure A) were removed from one of the other shutters that was beyond repair.

• The objective is to install the salvaged louver onto the shutter where replacements are needed. Because the shutter being repaired is already assembled, the dowels of the replacement louver (figure B) must be shortened slightly so that they can be fit into the existing holes shutter frame.

  Figure A

  Figure B

  
  

• Because these shutters have apparently had prior repair work, some brad nails need to be removed. A pry-bar is used to protect the adjacent wood as the brad nails are carefully removed using pliers (figure C).

• The dowels on the ends of the salvaged louver are sanded with 100-grit sandpaper to remove paint and prep the louver for installation. The sanded dowel is checked for fit in the opening (figure D).

  Figure C

  Figure D

  
  

• Because the dowels are still too long to permit insertion into the frame (figure E), a small amount of the dowel tip is removed using a utility knife (figure F).

  Figure E

  Figure F

  
  

• The tip is re-sanded smooth with 100-grit sandpaper. The louver can now be inserted into position in the shutter (figure G).

• The louver control-rod is attached to the salvaged louver using wire staples. To fasten the louver to the pull-rod, gently remove the existing wire staple from the louver (figure H) and apply polyurethane glue to the wire. Then reinsert the wire, first catching the wire loop on the pull-rod, then pushing the wire into its original holes

• These steps are repeated to replace any other damaged louvers.

  Figure G

  Figure H

  
  

General Repair and Reconditioning

• Clean and inspect condition of shutters and remove the old hardware.

• Sand and/or scrape and remove loose paint.

• Glue loose joints with polyurethane glue.

• Repair cracks and damaged wood with two-part epoxy wood filler.

• Sand repairs smooth.

• Prime and paint shutters.
  

  	Figure I
  	Figure J

• Determine how the shutters will be mounted to the window -- surface or flush mount.

• Select the appropriate style hinges for your shutter installation requirements (figure I). In our case, we opted for a Caribbean gravity-hinges (figure J) that would allow for the shutters to be installed so that they are flush with the outside edge of the house and still accommodate the storm windows.
  

• Fasten the hinges as per manufacturer's instructions to the window frame (figure K) and to the shutters (figure L).

• Install additional hardware to keep the shutters open or closed as needed. In our case, ordinary eye-hooks were used to hold the shutters secure in closed position.

  Figure K

  Figure L

  
  

  Figure M

• Once installation is complete, check the shutters for proper operation (figure M).

Note: This is a summary of steps included in the procedures shown in this episode of Restoration Realities. There may be variations in procedures for your particular restoration project based on the types of materials you select and the nature or extent of your particular project. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with materials or products that you select.

RESOURCES :

Victorian: American Restoration Style
Model: 0879058870
Author: Joan M. Brierton
Publisher: Gibbs Smith Publishers
Order this title from Amazon.com.

Renovating Old Houses: Bringing New Life to Vintage Homes
Author: George Nash
Publisher: Taunton Press
ISBN: 1561585351
Order this title from Amazon.com.

Renovating and Restyling Older Homes: The Professional's Guide to Maximum Value Remodeling
Author: Lawrence Dworin
Publisher: Craftsman Book Company
ISBN: 1572180293
Order this title from Amazon.com.

Selecting and Renovating an Old House: A Complete Guide
Author: United States Department of Agriculture
July 2000
Publisher: Dover Publications
ISBN: 0486409562
Order this title from Amazon.com.