Measure your window frame. Begin with the four planks that will serve as the shutter frame. Your shutter frame should be about .25 inches (or .6 cm) narrower than the window frame.
Cut the four planks to size.
Build the shutter frame by gluing the two vertical planks to the two horizontal planks.
Measure the length of your flat louvers. The length of the louvers should be 1/16th inch narrower than the opening between the two vertical stiles. The nylon louver pins that support the louvers inside the frame have a washer that is molded into the pin and is 1/32 inch in thickness. These washers prevent the lovers from contacting the inside edges of the stile resulting in smooth action. How many louvers you use depends on the size of the louvers and panel height.
Ideally, you should buy louvers already fitted to size. If starting from scratch, remember to leave room to securely attach pins with glue at either end of the louvers. Flat louvers are typically 2.5 3.5 or 4.5 inches in width.
Cut your louvers to size.
Mark along the inside face of the vertical stile on the shutter frame the spots where the louvers will go in. The louvers should overlap by 1/4 inch. Take great care to line up the markings on either side of the frame so that the louvers will sit flat.
Drill holes for the pins of the louvers on these markings.
Insert the louvers by placing the pins into the holes in the shutter frame. If you're having trouble getting the louvers in, drill the holes a bit deeper.
Measure and cut the tilt bar to stretch from the top horizontal plank to the bottom horizontal plank of the shutter frame. A wooden dowel that can swivel easily is ideal.
Drill holes in the top and bottom horizontal planks to accommodate the tilt bar.
Insert the tilt bar into the holes.
Secure the tilt bar to the louvers by shutter staples or threaded eyelets.
Test the shutters by moving the tilt bar up and down and observing the movement of the louvers.
Mount the shutter frame onto the window frame and secure it by screws or another method.
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