The Best Idea to Make Door Shutters The Height of Your Door

Y’all I had this idea to add shutters to our front doors. So the search was on for vintage shutters the height of the doors. The problem wasn’t finding shutters the correct height, it was finding some in good condition that we could afford.

I didn’t want to give up on the idea, so I devised this alternative plan to make door shutters for our front doors. Here is a step-by-step tutorial of how we did it.

The idea was to use the smaller shutters, that we already owned, and add extensions to make them taller

Why Make Door Shutters

First, I’ve had a pair of white vintage shutters propped by our front doors for a few years.

When I painted the shutters black for fall, I loved the new color but felt they would look better if they were the doors’ height.

After several attempts to find old, taller shutters, we realized that finding exactly what we wanted at a reasonable price was daunting.

Therefore, another plan was born.

We could add to the existing shutters to make them tall enough.

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Materials & Tools for Project – Extend the Shutters

2- 6x8x1 lumber from Hardware Store (depending on your shutters, this width may vary)
Jig Saw
Biscuit Joiner
Miter Saw
Cordless Drill
Joining Biscuits
3/8″ Dowel Rod
Wood glue
Clamps for Woodworking

Construct Extensions

Before you begin, measure the length of your shutter and the distance from your porch to the bottom of your light fixture. Then measure from that point to the top of your door. This will determine the length of your extensions.

Important NOTE:

I’m using the measurements we needed to extend our shutters for today’s tutorial. Your exact measurements will most likely vary.

Once you have your measurements, you will begin using the miter saw to cut approximately 12 boards from the lumber.

Be sure to cut the boards to the exact width of your existing shutters. We needed 12 – 16 inch, long boards.

Next, use your biscuit joiner to cut and add biscuits to join 3 of the boards together.

Be sure to mark the placement of the biscuits so that the boards will align once glued together.

Use wood glue to secure the biscuits between the boards and the edge of each board.

Once the three boards are glued, use the clamps to hold them in place for approx. 30 minutes. After removing clamps, allow 24 hours before proceeding.

Repeat this process until you have four sections.

NOTE: We considered using a larger flat board to avoid gluing the sections together. However, we are glad we took the extra steps because the attachments look like shiplap and have more character than a flat board.

Prepare the Top Section

Because the top section will fit around the light fixture, careful measurements are needed to cut out for the opening.

Use the jig saw to cut the opening in the two top sections.

Stain and Paint Door Shutters

Once everything is dry, stain the sections and then paint to match your shutter. You can wait to paint just before installation; however, it’s easier to do in small areas that are easier to work with.

If there is any damage during installation, the paint is easy to touch up.

I always get asked why I stain before I paint, so I’ll explain. The original shutters were dark brown before I painted them. For the paint color to look uniform, stain the wood first, and you will not be able to see a difference.

Attach the Bottom Section

To attach the bottom section, use the biscuit joiner to cut and join the bottom of your shutter to one of the sections.

Use wood glue to secure and add a clamp to hold until bond is set, approx. 30 minutes. Once again, allow to set for 24 hours before proceeding.

Attach Top Section to Door Shutters

Next, you will want to use your biscuit joiner and drill to create a way to join the top section to the shutter top. Align the top section to the top of the shutter, with the cutout area at the bottom.

Glue the biscuit and dowel rod into the shutter only. Be sure that the holes drilled for the dowel rod allow the shutter and top section to meet.

Drill holes in shutter and add dowel rods and biscuits to secure the additional extension piece.

Install Door Shutters

Begin by aligning the shutter under the light fixture and then bring the top section over the top, as shown below.

Door Shutter extension pieces slide right onto the top of the shutter.

Allow the dowel rods and biscuits to slip into the top section.

We did not glue the shutter to the top section because we might want to remove the shutter at a later date. It is easy to slip the top piece off to remove it.