How to Make a Wood Beam Fireplace Mantel

Introduction

In this tutorial, you will learn how to create a beautiful oak beam fireplace mantel from scratch. The process involves selecting the right materials, cutting, assembling, and finishing the mantel to enhance your living space. This project is perfect for DIY enthusiasts looking to add a rustic touch to their home.

Chapter 1: Prepare the Boards

To begin, gather your materials and prepare the boards for your mantel.

1. Select your wood: Purchase rough-sawn oak boards from a local hardwood store.
2. Rough cutting: Cut the boards slightly larger than the final dimensions to make them easier to handle.
3. Planing: Use a planer to reduce the thickness of each board to three-quarters of an inch.

Chapter 2: Cut the Boards

Next, you will cut the boards to the required dimensions.

1. Beveled cuts:

   • Set your table saw to a 45-degree angle.
   • Rip beveled cuts along the front edges of the top and bottom pieces.
   • Flip the boards, placing the beveled edge against the fence, and rip them to a depth of 8 inches.

2. Miter cuts:

   • Set your miter saw to 45 degrees and cut one end of the boards.
   • Measure 68 inches for the width, mark it, and cut the opposite bevel on the other end.

3. Front board:

   • Cut the front board to 6 inches wide by setting the saw fence to 5.25 inches (to account for the blade).
   • Cut the board to length, leaving extra length for later adjustments.

4. Frame pieces:

   • Cut four rectangular pieces equal to the width of the flat side of the front board and three-quarters of an inch shorter than the length of the flat side of the top and bottom pieces.

Chapter 3: Assemble the Beam

Now it's time to assemble the mantel.

1. Drilling pocket holes:

   • Mark where pocket holes will be drilled on the frame pieces and use a pocket hole jig to drill them.

2. Attaching frame pieces:

   • Clamp the frame pieces to the inside of the bottom board, ensuring even spacing and alignment with the beveled edges.
   • Position the top board, clamp it, and screw the ends together using a right-angle adapter for tight spaces.

3. Adding glue blocks:

   • Cut small blocks from scrap oak, align, and glue them along the beveled edges.
   • Test fit the front board, then apply glue to the edges and blocks, and clamp everything in place.

4. Securing the front:

   • Use pocket holes to screw the frame pieces to the front board.
   • Pre-drill and add trim screws through each glue block while clamping in place.

5. Creating side pieces:

   • Use leftover pieces for the sides of the beam, cutting bevels in the opposite direction to match grain patterns.
   • Mark, cut to length, and secure with glue and screws.

6. Adding a French cleat:

   • Cut a strip of plywood and rip a 45-degree bevel.
   • Glue the top of the cleat to the frame and secure with wood screws.

Chapter 4: Test Fit

Before finalizing the assembly, ensure everything fits properly.

1. Measure and mark:

   • Measure from the bottom of the beam to the top of the fireplace surround for the cleat placement.
   • Tackle any obstacles (like bump outs) by removing boards as necessary.

2. Adjust cleat placement:

   • Test fit the beam and adjust the cleat's height if needed for proper alignment.

Chapter 5: Finish and Install

Finally, finish and install your mantel.

1. Sanding:

   • Sand all surfaces with 220 grit sandpaper and round over seams with a screwdriver shaft.
   • Hand sand corners for a smooth finish.

2. Staining:

   • Apply a coat of stain in the direction of the grain, wiping off excess after a few minutes.
   • Allow the stain to dry overnight.

3. Filling gaps:

   • Use a colored match wood filler for larger gaps, wiping excess while wet for a clean look.

4. Applying polyurethane:

   • Apply a coat of white bond polyurethane, sand lightly with 320 grit between coats.
   • Repeat for a total of six coats for durability.

5. Mounting the beam:

   • Glue blocks to the ends of the wall cleat, position the beam, and secure with trim screws.
   • Consider additional screws into the studs for extra stability.

6. Final touches:

   • Replace any removed bump out boards and secure them back in place.

Conclusion

Congratulations on building your oak beam fireplace mantel! This step-by-step guide provides all the necessary actions to create a stunning focal point in your home. For further projects, consider exploring other woodworking tutorials or expanding your skills with additional techniques. Happy building!