How to Build a Faux Fireplace

Materials:

plywood
large mending plates
drill
screws
poplar lumber
MDF
jigsaw
table saw
wood glue
nails
hammer
brad nails
crown molding
1/4" luan plywood
220-grit sandpaper
tack cloth or rags
flush spackling compound

Steps:

1. Cut the back top panel and the two side legs out of plywood to the desired size. Secure them together with mending plates on the back.
2. Since the edges show, cut narrow pieces of poplar to cover them. To make the strips, select a piece of poplar that's long enough and the same width as the plywood. Set up the table saw to rip a 1/4-inch trim strip. Make several of these as they'll be used on both sides and around the firebox opening. Cut the trim strips to length if necessary and use wood glue and finish nails or a brad nailer to hold them in place. Or, purchase small detail trim for this step.
3. The second layer of the mantel is the arched detailing on the top and side legs made out of MDF (medium-density fiberboard). Draw the curve in the top piece and cut it out using a jigsaw. Sand the edges smooth and remove the dust with a tack cloth or damp rag. Put wood glue on the back of the panel; set it in position on top of the back top panel, and then secure it with nails.
4. Cut the side legs and add them to the backboard. Mark their position, and then add glue and finish nails along the edge to secure them.
5. The mantel is a 1x8 piece of poplar positioned to start at the edge of the backboard and overlap the front facing. Add details like crown molding and trim on the legs to give the fireplace as much or as little personality as desired.
6. Cut a piece of luan to fit where the firebox would be and attach it using glue and finish nails.
7. Fill the holes with spackling compound and sand the entire piece once dry. Prime, and then paint as desired.