Help Around the House host Henry Harrison shares some basic masonry skills to help a guest replace the access door at the back of a chimney (
figure A). On his elbow grease scale of one to four, Harrison gives this job a three.
Tools:
brick hammer
brick chisel
pencil
carpenter's square
screwdriver
brush
trowel
regular bucket
mortar mixing bucket
safety glasses
clean-out door
mortar
extra bricks
Steps:
1. Clear away old mortar around opening using the brick hammer and brick chisel. Also remove any loose bricks and expand the opening if necessary to create an even border for the new clean-out door (figure B).
2. Thoroughly clean away the debris from the loose mortar.
3. Cut replacement bricks to size by first marking a line on each side of the brick using the carpenter's square and pencil (figure C).
4. Place the brick on a soft surface, such as the lawn or bag of sand, and score along the line using the hammer and chisel to break the brick along the line (figure D). Do not attempt to cut bricks on a hard surface such as concrete as they may shatter.
5. Mix mortar according to instructions. Dampen the surrounding surface where the mortar will be applied.
6. Spread an even layer of mortar on the base first, then build up a layer on the side of the opening (figure E).
7. Butter the side and top of each brick before setting it in place (figure F). Buttering is the process of building up a mound or peak of mortar on the top or sides of the brick.
8. Use the trowel to cut away any excess mortar. If any mortar falls out when the brick is inserted, just tuck new mortar into the gaps until it is well seated.
9. When the frame is finished, spread some mortar on the top flange of the new door (figure G), then carefully ease the door into the cavity (figure H ).
10. Place nails through holes in the doorframe and into the soft mortar. Once the mortar dries the nails will add extra holding power.
11. Lean something heavy against the door while it dries (figure I), and allow it to set for at least a few days before using the door.
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