DIY Window Shutters over AC Unit

This project provides a creative, attractive way to hide a wall AC unit.

DIY Window Shutters over AC Unit

This project provides a creative, attractive way to hide a wall AC unit.

Difficulty: Difficult

Materials
(2) Pine wood lumber at 33" × 7" × 1"
(2) Pine wood lumber at 27½" × 7" × 1"
(6) Pine wood lumber at 29" × 5½" × 1"
(4) Pine wood lumber at 16 3/8" × 3½" × 1"
Wood glue
Protective eyewear
Leather and rubber gloves
Pencil
Tape measure
Chop saw
Jigsaw
Sander
100-grit sandpaper
T-square or straight edge
Nail gun
1" finishing nails
Drill
(4) hinges with ½" screws
Latch with ½" screws
Light oak colored wood stain (or color of choice)
Paintbrush
Dry rag
(1) Douglas fir wood lumber at 20" × 2½" × 1"
2½" wood screws

Note: If you do not own a chop saw or don’t feel comfortable using one, have the wood precut at a hardware store.

    Steps

    Making the Frame
  1. Line up one 33" × 7" × 1" lumber with one 27½" × 7" × 1" piece to create a 90-degree angle. Run a bead of glue along the edge of one piece, and then press them together, making sure the pieces are flush against each other

  2. Drive three nails into the side: one at the top, one in the middle and one at the bottom
  3. Repeat steps 2 and 3 by connecting the remaining 33" × 7" × 1" and 27½" × 7" × 1" boards to create a frame


  4. Making the Shutters
  5. Lay the six 29" × 5½" × 1" boards side by side on the work space, separating half of them so three are on one side and three are on the other. Set the four 16 3/8" × 3½" × 1" pieces aside
  6. Measure and mark 8" down from the top edge of the first set of three boards. Place one 16 3/8" × 3½" × 1" piece across the mark and drive two nails through the 16 3/8" × 3½" × 1" piece and into the top and bottom of each 29" × 5½" × 1" board, totaling four nails per 29" board and 12 nails in the 16 3/8" board


  7. Repeat step 6 for the lower half of the shutter
  8. Repeat steps 4 through 6 to create a second shutter


  9. Attaching the Shutters
  10. Bring the frame back to the workspace. Measure and mark 4" from the top and bottom on both side edges
  11. Place one hinge on the mark and drill in three ½" screws. Add hinges on all marks from step 8


  12. Line up one shutter with the edge of the frame. Flip one hinge up so the second half of the hinge is flush with the shutter, and secure the hinge onto the shutter with three ½" screws. Attach the second hinge to the shutter


  13. Carpenter’s Tip: Though marking a line is not necessary, it helps to remind you where the hedge is supposed to be in case you move it.



  14. Repeat step 10 to add the second shutter to the frame


  15. Staining the Shutters
  16. Lightly sand the entire shutter box
  17. Dip the rag or paintbrush into the wood stain and cover the entire shutter box. Allow to dry for 30 minutes
  18. Bring the shutter box to the unit you’d like to cover. If the box needs an opening for the plug, measure how wide it needs to be and mark the measurements on the box. Use the jigsaw to cut out the opening

  19. Find the midpoint where the two shutters meet, about 6¼" from either 16 3/8" × 3½" × 1" piece, and attach a latch to the doors


  20. Installing the Shutter Box
  21. Place the 20" × 2½" × 1" lumber on the wall directly above the AC unit. This will act as a cleat and support to hang the shutter box. Drill it in place with a 2" wood screw in each wall stud

  22. Set the shutter box on top of the wood cleat. Measure 2" in from the edge and secure the shutter box in place by drilling 2" wood screws through the top of the shutter box into the cleat every 4"