How to Build a Shaker Fireplace Mantel and Surround Built-in | Woodworking DIY Project Plans

Most of the materials can be found at your local hardware store and on Amazon.

• Poplar Wood 1×3 = 36ft
• Poplar Wood 1×4 = 6ft
• Poplar Wood 1×6 = 24ft
• Poplar Cove 9/16×3-1/2 | goo.gl/uZ2kS6
• Poplar Mantel 1x5x60 | https://bit.ly/2yrsKgw
• Pine 1×6 = 6ft
• Pine 2×4 = 8ft
• ¼ in MDF = 2”x4” (2x)

• Miter Saw | https://amzn.to/2XgnJCo
• Table Saw | https://amzn.to/2XfJliB
• Drill Kit | https://amzn.to/2FKP6tG
• Orbital Sander | https://amzn.to/2LFAMqn
• Nail Gun Kit | https://amzn.to/2LwpNzi
• Air Compressor | https://amzn.to/2LyID95
• Tap Measure | https://amzn.to/2wGQGLU
• Paint Brush Kit | https://amzn.to/3dCRguW
• Kreg Face Clamp | https://amzn.to/2ygTW17
• Kreg Jig pocket hole screws for 3/4in wood | https://amzn.to/2L0U1cJ
• Kreg Jig Pocket Hole Kit | https://amzn.to/2LLS6ZC
• Hammer | https://amzn.to/2Xgl4WP
• Rubber Mallet | https://amzn.to/2WP7pXs
• Level | https://amzn.to/2XkTOGD
• Freud Dato Blad | https://amzn.to/3bNodTf
• Tape Measure | https://amzn.to/2LIUkZE
• Rubber Grout Float | https://amzn.to/3e5JDwd
• Square Notch Trowel | https://amzn.to/3bNoCFf

• Wood Glue | http://amzn.to/1YpJiqd
• Caulk | https://amzn.to/36fuTbs
• 5 in Wood Screws | http://amzn.to/1SZAQfN
• 1gal Pure White/Base 1 Semi-Gloss Interior Paint | https://homedepot.sjv.io/zdP2O
• Carrara White Marble | http://amzn.to/1YpJyFH
• White Thin Set Mortar | http://amzn.to/23p73FA
• White Grout | http://amzn.to/1NkKAwL
• Long Nails | http://amzn.to/1S18kbl
• Short Nails | http://amzn.to/1NkKCov
• Ultraset SF | https://bit.ly/3cWbf6U
• 1/8in Tile Spacers | https://amzn.to/2WOC5rW
• 5 Gallon Bucket | https://amzn.to/2Tr08v2
• Grout Sponge | https://amzn.to/2LOyrrG

Laying the tile was probably the most challenging part of the build. When you are laying tile around a fireplace you need to keep in mind that the walls and surround are going to get very hot. The heat from the wood or gas burning fireplace release a lot of thermal heat into the room. Be sure to consult your firebox manual and local codes to ensure you are installing everything correctly.

I built a wooden frame/bridge to help hold the tile in place. I would recommend watching my Shaker Fireplace Build video to see how I installed the marble tile around my fireplace.

The other thing you need to remember is that you cannot lay tile over metal without some type of membrane. The reason is that the mortar can’t adhere to metal it will just slide off and/or dry and crack.

I did a lot of research and came across a great product Ultraset SF by Bostik. You can purchase Ultraset SF online or your local tile dealer may be able to order it for you. This stuff worked great and did the job however be mindful that you need/must to wear gloves, I didn’t realize how sticky it is to work with. It has the consistency of thick putty or really sticky chewing gum. You don’t want to get this stuff on your hands it will not come off easily, trust me I learned the hard way!

I would purchase the G & F 3100 Knit Glove with Textured Latex Coating from Amazon, you will be glad you did. This will give you the textile feedback you need to get the job done and won’t break down or fall apart if the Ultaset happens to get on them.

I would recommend watching my video showing you how to build and assemble a shaker fireplace. This video will help you if you download my shaker fireplace surround plans or have purchased the shaker fireplace kit.

The Shaker Fireplace Kit includes pre-cut materials to assemble this amazing shaker fireplace surround. It is important to note that the kit does not include the mantel section (mantel, crown molding & mounting material). The reason why the kit does not include the mantel section is to keep the cost of the kit to an affordable price. Customers and DIYers have different needs when it comes to lengths and depths of. their mantel. In additional shipping costs greatly increase when packages reach a specific size and weight. My goal is to provide you the most flexible and modifiable Shaker Fireplace Surround Kit possible.

Building a fireplace surround and mantel is not as hard as you might think. It just takes planning and forethought. The biggest challenge to building a fireplace mantel and surround is figuring out how you are going to attach the surround to the wall. I overcame this challenge by installing 2×3 blocks of wood to the drywall using liquid nails and screws. You can see by the picture that the 2×3 blocks of wood are screwed into the drywall and that I then placed the boxes I made over the blocks to hold them in place.

Once the boxes were in place I simply used my nail gun and nailed them to the block of wood. This technique proved to be a really good technique to getting a seamless and clean install of the boxes on the left and right of my surround. I have to be honest, it was one of my most favorite parts of the build. There was something really gratifying about attaching the boxes to the wall. I only wish I took more pictures of the process.

The next step is to install the crown molding or whatever design feature you have or want to add to your mantel. This part was rather easy. I would recommend watching my video on how to cut the trim

Once your crown molding is installed you are now ready to install the mantel. I used the same technique that I used for installing the side shaker boxes to the drywall. I simply placed and secured wooden blocks evenly inside the shaker center box using my nail gun and liquid nails. These blocks provide support for the mantel as well as something to drill and screw the mantel to. Once the blocks were secure all I had to do was place my mantle on top and screw it in place and cover the screw holes with wood putty and prep for painting.

I really enjoy painting things like furniture and odd stuff, however I don’t like painting walls and find it rather boring. Before I painted the surround I had to caulk the cracks and fill any holes with wood putty. This is a very, very important step. You want to make sure the surface of where you are going to paint is as smooth as possible. Most people think that all you have to do is sand and sometimes that is true but most of the time you need to go one step further. I used caulk because the fireplace will emit a lot of heat.

Wood putty will crack under heat and that is why you should always use something like caulk for cracks when the situation permits. I ended up giving the fireplace surround 3 coats of paint. The paint I used is from Sherwin Williams and it is important to note not all paints are equal. For furniture or carpentry you should use the highest quality paint you can afford. If you are interested in the specific color just leave me a comment. Below is a picture of what it looked like before I painted it and next to it is the final coat of paint.

 Below are several ways to pin, share, and like this project. If you have any questions please feel free to leave a comment.