How to build a wooden fireplace surround with a classic mantel

Building a wooden fireplace surround with a classic mantel can be an enjoyable woodworking project that adds character to any room. A well-crafted fireplace surround can serve as a focal point in your living space, and with a few basic tools and materials, you can create a stunning, traditional design. Here’s a step-by-step guide to help you through the process.

Materials and Tools Needed

Materials:

• Hardwood (such as oak, maple, or cherry) for the mantel and surround
• MDF or plywood for backing (optional)
• Wood glue
• Wood screws
• Wood filler
• Sandpaper (fine-grit)
• Paint or stain (optional)
• Finish (polyurethane or varnish)
• Trim (optional for decorative detailing)
• Brackets for mantel support (if required)

Tools:

• Tape measure
• Level
• Miter saw
• Jigsaw (for cutting intricate shapes)
• Drill and drill bits
• Clamps
• Hammer
• Nails (finish nails)
• Screwdriver
• Sanding block or electric sander
• Paintbrush (if painting or staining)

Step 1: Plan and Measure

Before you begin building your fireplace surround, it’s important to plan out the design. Measure the dimensions of your fireplace opening and the surrounding wall. A classic mantel design typically includes a shelf (mantel), vertical sidepieces, and a decorative header that stretches across the top of the surround.

• Mantel Width: The mantel should extend several inches beyond the edges of the fireplace opening. A common width is 6 to 8 inches on each side.
• Height: The height of the surround typically varies between 48 to 54 inches, but it can be adjusted based on personal preference or the room’s dimensions.
• Depth: The depth of the mantel will usually range between 6 and 10 inches, depending on the design.

Create a sketch or drawing with these measurements so you have a clear visual of what you’re aiming for.

Step 2: Prepare the Wood

Once your design is set, you can begin preparing the wood for the fireplace surround.

1. Cut the Main Pieces: Use your miter saw to cut the vertical sidepieces (legs) and the header that will span the top of the surround. The vertical pieces will frame the sides of the fireplace, while the header piece will form the top of the surround.
2. Cut the Mantel: The mantel shelf can be cut from a single solid piece or two joined pieces. Make sure to check the length to ensure it overhangs your fireplace opening as planned.

Step 3: Build the Surround Frame

Now that the basic pieces are cut, it’s time to assemble the frame for the surround.

1. Attach the Vertical Legs: Position the vertical pieces (legs) on each side of the fireplace opening, ensuring they are level and aligned. Use wood glue to secure them, then reinforce with wood screws. You can drill pilot holes for the screws to avoid splitting the wood.

2. Install the Header: Position the header piece at the top of the vertical pieces. Use wood glue and screws to secure it in place. Make sure it is level and aligned properly.

3. Add the Back Panel (Optional): Some surrounds have a back panel to cover the area between the legs. If you are adding one, cut a piece of MDF or plywood to fit the width between the legs and the height of the surround. Secure this piece with wood screws or nails.

Step 4: Attach the Mantel

The mantel will sit on top of the surround frame. This is often the most visually striking part of the design, so it should be properly supported.

1. Prepare the Mantel Support: Depending on the size and weight of your mantel, you may need to add support brackets underneath. Secure the brackets to the wall studs or surround frame to ensure the mantel will hold.

2. Install the Mantel Shelf: Position the mantel shelf on top of the surround frame. Apply wood glue to the top edge of the frame, and carefully place the mantel in position. Use wood screws to attach it, making sure the screws are driven into the frame behind the mantel so they are not visible. Alternatively, use finish nails for a cleaner look.

Step 5: Add Decorative Trim (Optional)

For a classic look, you can add decorative trim to enhance the appearance of the surround.

1. Measure and Cut the Trim: Use a miter saw to cut the trim pieces at 45-degree angles for clean joints. You can use simple casing trim or more elaborate molding, depending on your desired style.

2. Attach the Trim: Apply wood glue to the back of the trim pieces and press them into place on the vertical legs, header, and around the base of the mantel. Use finish nails to secure the trim in place.

Step 6: Sand and Finish

Now that the structure is assembled, it’s time to finish the surround.

1. Sand the Surface: Use a fine-grit sanding block or electric sander to smooth all surfaces. Sand down any rough edges or seams where the trim pieces meet the frame.

2. Fill Gaps: If you have visible nail holes or gaps in the joints, use wood filler to fill them. Let the filler dry and then sand it smooth.

3. Stain or Paint: Depending on your preference, you can stain the wood for a natural look or paint it to match your room’s decor. Apply a couple of coats of finish or sealer to protect the wood from heat and wear.

Step 7: Install the Surround

Once the surround is fully finished and dry, it’s time to install it around the fireplace.

1. Position the Surround: Carefully position the fireplace surround against the wall. Ensure it is centered and level.

2. Secure the Surround: Use screws or nails to secure the surround to the wall studs or use brackets for additional support. Make sure it is securely attached so that the mantel remains stable.

Step 8: Final Touches

Once the surround is installed, you can add any final touches, such as decorative accessories, fireplace tools, or candles, to complete the look. A well-built wooden fireplace surround with a classic mantel is sure to be a timeless addition to any room.

Building a fireplace surround is a challenging yet rewarding project that can transform the appearance of your living space. With careful planning, proper measurements, and attention to detail, you can create a beautiful and functional surround that complements your fireplace and enhances the aesthetic of the room.

For those looking to enhance their woodworking skills and tackle more ambitious projects like this one, Teds Woodworking offers detailed plans and guides that can help turn your ideas into reality. Check out Teds Woodworking Course here.