Fireplace Freestyle Fiddling #4 It’s Mantle Time

I know this is a long drawn out series – but there’s more components than average to this build, due to the flanking bookcases.

1-checking-the-taperThe tops of the bookcases are slightly sloped intentionally – and because of this the side panel will need to be tapered. First a level is placed on top and the gap is measured for the taper. This is how much we will remove from the bottom to make the top level.

2-trper-jigI use a tapering jig, but you can use a homemade version just as well. This will add a slight taper to our side pieces.

3-squaring-the-sideOnce we have the pieces cut we then need to square the sides to the window casing. I used a framing square and shim out the side piece so everything is now square.

4-tapered-sideA piece is cut for the side top reveal.

5-side-paintedAn additional piece is cut to wrap around the front of the marble top. It is then painted before attaching.

6-mantle-roughNow we’re ready to make the mantle. This is a 5/4 (1″) X 10 clear white pine board. I just set it up to get an idea of the overhang.

7-back-band-cutI decided to make a back-band to go at the back of the mantle. I used a router to add some detail to the top and then cut the three pieces. Here I’m test fitting the cuts.

8-mantle-sides-joinedThe three back-band pieces are glued and nailed together, I then joined the front mantle to the side pieces with a biscuit and glue.

9-mantle-glue-upThe mantle and back band were all assembled as a one piece unit to keep everything flat and straight.

10-test-fit-mantleThen the assembled mantle was test fit into place.

11-painting-back-bandThe back band is finished and a hole was drilled in each side leg of the mantle. I made the side mantle top slightly narrower to make the joint easier to finish and not have to be concerned about the joint separating.

12-mantle-wiringWiring from a wall switch is run under the mantle to both sides of the fireplace for the final test fit.

13-sillite-receptaclesThe wires were for these. Called Sillites, they will allow us to plug in Christmas lights or other decorations on the mantle.

14-attaching-the-mantleOnce the wiring is run we can finally glue and attach the mantle.

15-mantle-in-placeTime to start sanding and finishing.

16-fireplace-side-detailOne more detail is added to the side of pilaster to mirror the design in the sunroom.The paint is BM Ice White in Impervo enamel.

17-shell-detailI’ll sand and paint this a total of four times. I start will 100 grit and finish with 400. It is tedious, but when it’s finally done you can feel the difference.

18-sillite-receptacleThe Sillites have a cover when not in use.

19-finish-paintingSo you think we’d be done – but nooooo – we still have to finish the original details on the bookcases – and slide the fireplace in there.

One more post on this thing and I’m outa here – promise.

 

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Fireplace Freestyle Fiddling #3 Almost there

If I’m going to have a roaring fire in this thing by Christmas, I better get a move on finishing the surround.

Let’s Continue, Shall We?

1-fireplace-blockI added small extension blocks to the tops of the pilasters to create some depth and add some dimension. The pilasters are just press fitted to the side pieces that have been attached to the fireplace. The crosspiece is not installed.

2-fireplace-corner-blockA little silicone is used to attach the carved corner decorations to the corner boxes. Again, I used silicone in case I had to pry these puppies off and keep damage to a minimum.

3-pilaster-baseI added a small foot to the base of the carved facing pilaster. Behind the ornamental element is another piece with a bevel cut to match the foot. The base is pre-painted to make final finishing easier.

4-finished-pilasterAll the design elements are in place for the pilasters. The floating crosspiece is slipped in and two scrap sticks are used to keep it in position.

5-pilaster-alignmentHere’s where those floating front pieces come into play. The top crosspiece shows how crooked the face of the pilaster is in relation to the fireplace front at the top. The base of this pilaster is flush to the fireplace – pretty skewed.

6-pilaster-daddoBecause we didn’t attach the front piece to the side we can pivot this just a little to square the face to the front of the fireplace. Since the fireplace is a little skewed you can see the top is slightly out of the bottom of the dado.

7-aligning-fireplace-pilastersBy clamping and attaching the top crosspiece to the pilasters we can tighten the legs and remove any gaps between the pilasters and fireplace. The lower crosspiece is still not attached. Make sense?

8-crosspiece-frameNow we can make the crosspiece overlay. This will be mounted to the main face crosspiece that has yet to be permanently attached.

9-crosspiece-optionThe piece is constructed to frame the center carving and have two side elements. I originally thought I would have two raised panels, but didn’t like the design.

10-fireplace-first-assemblyThe crosspiece frame we just made is attached to the floating crosspiece. The frame is then attached to the top piece that bridges the pilasters. Only now are all the elements attached to each other. That’s a lot of steps to put three sticks together.

11-routed-trim-moldingSince we made recessed panels on either side of the center carving, we need to add the same detail to the recessed edge that the carvings have. A small router bit created the profile and then two trips through the table saw makes the proper shape.

12-trim-molding-set-cornerThe pieces are cut and fitted to the inside of the recess.

13-trim-in-placeNow the recessed panels match the carvings.

One more post and we’ll be on to the next – come along – it’s getting interesting.