A carpenter friend, Terry Breza, needed to replace eight shutters on an old brick home. Fixed-louver wooden shutters are common on traditional homes in our area, but they're often in bad shape (1). Making the numerous angled mortises in the stiles and assembling all the parts is a daunting task, so mostly the old shutters get patched with filler or just rot away. Since Terry didn't have the budget for new custom shutters, he called me to see if I could figure out a cost-saving production method for making replacements. Always up for a challenge, I invited him over to the shop for some brainstorming.


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