Punched Copper Fireplace Screen

copper panel
mahogany wood frame
scrap piece of 3/4" plywood
tin snips
metal punch awl
hammer
radial arm saw
table saw
electric sander
sandpaper
biscuits and biscuit jointer
wood glue
copper cleaner
sal ammonia solution in a spray bottle
2 clamps
drill
power screwdriver and screws
linseed oil
newsprint
permanent marker
carpenter's pencil
leather gloves
safety glasses
dust mask
painter's tape
clean rags

1. Wear leather gloves to prevent cuts from the copper's sharp edges. Cut a 15" x 20" copper panel with tin snips.

2. Draw the selected design on newsprint with a permanent marker. Tape the heart design to the copper panel (figure A).

3. Punch holes 1/4 inch apart along the lines of the fireplace screen design with a hammer and metal punch or awl (figure B).

4. After the copper fireplace screen design has been completely punched (figure C), apply the copper cleaning solution over the entire copper panel with a rag or sponge. When the cleaner has dried to a smoky film, use a clean rag to wipe and polish the copper.

5. Place the punched copper panel on pieces of newsprint. Wearing safety glasses and a dust mask, spray the clean copper panel with sal ammonia to create an aged patina (figure D).

6. Measure and cut wood for the frame and stands that will hold the punched copper fireplace screen panel.

7. Cut recesses into the wood frame pieces with a biscuit jointer (figure E) that will eventually hold glued wood biscuits when the frame is assembled around the copper panel.

8. Wear safety equipment and using a table saw, cut a groove into the inside edges of the frame for the copper fireplace screen panel to rest in when the frame is assembled around the panel (figure F).

9. Sand the wood frame and stands.

10. Assemble the wood frame around the punched copper panel using wood glue and biscuits (figure G).

11. Clamp the frame together, wipe off excess glue, and allow glue to set and dry (figure H).

12. Sand the wood frame and stands to a smooth even surface.

13. Attach the wooden stands to the bottom of the frame with screws, drilling the holes first (figure I).

14. Apply the linseed oil finish according to manufacturer's directions to the punched copper fireplace screen (figure J).

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