This is a temporary low-cost method for protecting windows from airborne debris during severe storms or hurricanes for homes that already have operable (fully functional) exterior shutters installed. Operable wood or composite shutters are typically not storm-proof because they are not strong enough to withstand flying debris in high winds. While it is recommended to install "rated" shutters rather than using this method if your budget allows, this is an alternative to save some money if you need storm protection inexpensively and you are running short on time.

The least expensive way to convert your exterior shutters is with a reinforced plywood cover. You should try to prepare your shutters as early as possible to ensure that your local home improvement stores don't run out of the necessary materials. Also, this method should be considered temporary because plywood will not last long in an exterior environment even with good priming and painting. However, temporary storm protection can be achieved using your existing functional exterior shutters as a platform for fortifying your home against severe weather.

Before The Storm

To prepare, rough measure the windows you will be covering and purchase the appropriate thickness of plywood. This will of course depend on the severity of the storms in your area, but using at least 5/8" thick exterior grade plywood is what the Atlantic Oceanographic and Meteorological Laboratory recommends. You should also purchase enough 1 1/2" (or longer if your plywood is thicker) screws for every 10" around the perimeter of the windows, and ensure you have a pair of saw horses handy.

Remove the shutters from the house (you may have to remove the bottom hinge to do this) and lay them on the saw horses as with the outside of the shutters facing upward as if they were in a closed position. Measure the exact size of your shutter pair and make a cutout from plywood that is the exact size as the outer height and width of the closed shutter pair. Now lay the plywood on top of the shutters and place a mark at the half way point of the shutter frame at every 10 inches. Remove the plywood from the top of the shutters and drill pilot holes to accommodate the shank of the screws that you purchased. Do not drill the shutters until you are preparing for the storm - it is important to keep them sealed from the elements so they won't deteriorate from the elements.

Next, label the plywood using a permanent marker or spray paint indicating the window that it will be installed over ("living room", for example). Once your panels are done, you may waterproof them with a coat of varnish or paint (just don't paint over your markings).

Finally, staple a zip lock bag with the right number of screws on the back of each panel so they won't get lost. Find a cool, dry place to store the plywood because both heat and moisture can lead to warping, which will affect their fit.

Storm Preparation

When the storm inevitably arrives, remove the plywood cutouts from storage and one by one take down the appropriate shutters and drill them to the appropriate size and depth to accommodate the screws. Be sure not to drill too large of a hole or the threads will pull out during high winds. Also, be sure you are drilling the outside surface of the shutters. Reinstall the shutters to the window opening, close and bolt the shutters closed, and then drive the screws in place using an electric drill.

After The Storm

When the storm has passed, you can remove the plywood by unscrewing it from the shutters. Be sure to seal the screw holes up with paintable caulk and then you can paint over the screw holes.

Once again, the method described in this article should be considered temporary storm protection and you should plan to install "rated" hurricane shutters for permanent protection. Dade and Broward counties and the Keys require more stringent requirements for storm protection and in those areas you should not consider this alternative method.

This article is (c) copyright 2011 by ESSCO Exterior Products, Inc. You may republish this article on your web site or blog as long as you keep both the article body and this bio intact including the copyright notice and all hyperlinks.