Overview:
This project will show you how to build a fireplace mantel. A mantel provides a decorative frame for your fireplace and a focal point for the room. You can use a mantel kit from a home center or lumberyard or be creative and design your own from custom-milled moldings.
Materials:
fireplace mantel kit or premium wood boards and custom-milled moldings, nails, wood glue, sandpaper, wood-filler
Tools You'll Need:
10ft. or 25ft. tape measure, 4-in-1 level, 7oz. or 16oz. hammer, 6-in-1 interchangeable screwdriver, power-lite cordless drill
Before You Begin:
Check with your local building department for important fire safety guidelines, especially required side and top clearance between a fireplace opening and any combustible materials. These instructions also assume your fireplace has a noncombustible surround around the immediate firebox opening.
Barbara's Tips:
It's important to wipe off any excess wood glue using a damp cloth. Glue on the wood will prevent the stain from adhering properly.
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Step 1: Plan the Design
Have accurate measurements and make a scale sketch of your fireplace. Use your drill to make holes where the materials will be installed to determine what kind of solid backing (if any) is behind the wall where the mantel will be installed. If you are designing your own mantel, buy samples of available moldings and use wood glue to assemble short models of the sides, frieze board and mantel shelf to help you visualize the design. When you have your design exact, ask your lumber center to mill the moldings to your specifications.
Step 2: Build the Base
Attach the wood surround to the wall using appropriate fasteners. Try to locate the fasteners where they will be covered by moldings. Countersink any fasteners that are not covered. You can fill the holes later.
Step 3: Mold your Mantel
Because you followed the golden rule of "measure twice, cut once" when ordering your custom-cut moldings, everything will fit precisely. If not, you may need a power miter saw to make adjustments. Glue all joints, wiping off any excess glue with a damp cloth. Attach molding to surround with finishing nails. Countersink any visible nails.
Step 4: A Final Polish
Sand and clean the surface of the mantel. Tape off the wall and adjoining areas with painter's tape. Apply stain, and then smooth the surface with steel wool, before applying at least three coats of polyurethane or other protective coating. If painting, use a primer, followed by two or more coats of trim paint.
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