DIY Shutters That Last: Building with Azek

Ever thought about adding a touch of timeless charm to your home’s exterior? Shutters can do just that, enhancing your windows while adding a stylish flair. Brian recently embarked on a DIY journey to create shutters using Azek, a PVC material that mimics wood’s beauty but with enhanced durability and low maintenance. In this blog post and video, we’ll guide you through the entire process, from measuring your windows to installing the final piece so you can build this on your own. Whether you're a seasoned DIY enthusiast or a beginner, this step-by-step tutorial will help you craft shutters that stand the test of time. 

Why Should I use Azek to build shutters?

Azek is a fantastic choice for building shutters due to its many advantages: Azek is an excellent choice for durable, low-maintenance construction, as it is resistant to rot, decay, and insect damage. It mimics the qualities of wood, being easily cut, sanded, and painted, yet requires minimal upkeep beyond occasional cleaning. This material is also weather-resistant, making it ideal for outdoor applications, even in harsh conditions.

What do I need to consider as I plan to build my shutters? 

When planning your shutters, first decide whether they will be functional or purely decorative. Meaning, do you want them to be operational? In this video, Brian makes his shutters as a complementary decoration to his home. 

Next, measure the window opening and select a design that complements your home's architecture. Brian decided to make a starfish cutout to go with the aesthetic of his home. 

Before you begin, gather the necessary materials, including Azek boards, screws, adhesive, and any decorative elements you want to include. 

What materials do I need?

• Azek 1x4 boards
• Trim router
• PVC adhesive (like Azek's)
• Exterior screws
• Paint and primer (in one)
• Measuring tape
• Miter Saw 
• Framing square
• Clamps
• Speed square
• Jigsaw
• 80-grit sandpaper

Step-by-Step Guide:

1. Measure Your Window: Decide whether your shutters will be operational or decorative. For this tutorial, we’re going decorative.

• Measure from the top of the casing to the top of the sill (e.g., 49 inches).
• Decide on a width that suits your design preference.

2. Prepare the Azek Boards: Cut the 1x4 Azek boards to length. You’ll need enough for the vertical pieces, top, and bottom cross pieces.

• Use a trim router to add a decorative edge to all four sides of each board. This adds a nice finished touch.

3. Assemble the Shutters: Lay out your cut pieces on a flat surface.

• Use a framing square to ensure all ends are even.
• Clamp the pieces in place.

4. Attach Cross Pieces: Determine the positioning of your cross pieces (e.g., 3.5 inches from the bottom).

• Apply PVC adhesive to both surfaces where the cross pieces will attach.
• Use a speed square to line them up straight.
• Clamp the pieces together and let the adhesive set. To speed up the process, you can flip the shutter over and screw the cross pieces from the back.

5. Add Decorative Elements: Cut out shapes (like a starfish) using a jigsaw. 

• Clamp the shutter to your work table.
• Drill a starter hole for the jigsaw.
• Carefully cut out the shape. Sand the edges with 80-grit sandpaper for a smooth finish.

6. Paint the Shutters: Apply three coats of good exterior paint and primer in one. Let each coat dry thoroughly.

7. Install the Shutters: Pre-drill holes for the exterior screws.

• Attach the shutters to the house, starting screws while still on the ground for easier installation.
• To finish, dab some paint over the screw heads for a seamless look.

And there you have it, beautiful Azek shutters that will stand the test of time! By following these steps and using Azek, you can create stunning, long-lasting shutters that will enhance your home's curb appeal for years to come. If you enjoy working with Azek, you may like to read about the latest in PVC decking for your home. Follow us on social media and show us your designs!