Rediscovering a Fireplace and Adding a Mantel

The homeowners have more than an inkling that an old fireplace exists behind one of the walls in their living area. Steve Watson and crew help rediscover the concealed fireplace, get it prepared for use and install a new mantel. Following are a list of materials, some tips and the basic steps in the fireplace and mantel project.

Materials and tools:

3/4"birch plywood 3 (2 sheets)
crown molding (20 linear ft.)
picture molding (30 linear ft.)
table saw
power miter box
reciprocating saw
air compressor with hoses
cold chisels (for masonry)
finish nailer
sledge hammer
hammer
level
measuring tape
safety glasses

Steps:

1. Double check. Before you start tearing into drywall or plaster, make absolutely certain that there is a firebox behind the wall. Get on the roof and measure down the chimney to make sure it is not blocked. Drill an inspection hole to see if the firebox is still open

3. Open the wall. Start where you think the firebox is, and make a small hole. Carefully work out from the center until you hit all sides of the opening. Decide if you want to uncover the entire fireplace, or just opening the firebox.

4. Reveal. If you're exposing the entire fireplace, begin chipping away the plaster by scraping up and down, not inwards. This will save the face of the brick.

5. Rebuild. Depending on your design, rebuild a new surround or mantle.

Materials and tools:

2x4 lumber (6-ft. length; 1)
1x6 lumber (8-ft. length; 4)
Molding (varies by preference)
screws
air compressor with hoses
finish nailer
powder fastener nailer with loads and charges
cordless drill with battery and magnetic screw tip
power miter box
level
pencil
wood glue
safety glasses

Steps:

Measure area for mantle. If you are placing the mantle above a fireplace, be sure to measure a safe distance from any are where open flames will be present.

Attach ledger board to wall. Using a screw gun for drywall, or powder fastener for brick or stone, attach the 2x4 centered on the wall. Use the level to ensure that the ledger board even. This board serves to give the mantle additional strength and structure.

Measure and cut lumber to size. Use the miter box to cut your 1x6 to size, using a smaller-width piece for the vertical face.

Assemble mantelpiece. Using wood glue and the finish nailer, attach the pieces you have cut to make a box with one side open to accommodate the ledger board.

Attach molding . Select a molding that reflects your personal taste and also matches the existing decor. Remember to miter-cut 45-degree angles in the molding to match them up with minimal seams.

Fasten mantel to wall. Use the open end of the mantle to seat it over the ledger board, and attach with the finish nailer.

Stain or prime and paint to match existing decor.