How to Turn a Reclaimed Beam into a Fireplace Mantel | Ask This Old House

Ask This Old House carpenter, Nathan Gilbert, helps a homeowner turn a reclaimed mantel into a fireplace mantel.
SUBSCRIBE to This Old House: bit.ly/SubscribeThisOldHouse.
Time: 4 hours
Cost: $50 - $300
Skill Level: Moderate
Tools:
Drill [amzn.to/2KKMZeU]
Masonry bits [amzn.to/3pgZKwr]
Block plane [amzn.to/3mzmNRr]
Sandpaper [amzn.to/3asUXnL]
Tape measure [amzn.to/38oghrF]
Level [amzn.to/2LSOJDf]
Circular saw [amzn.to/2LYkkUf] or two-person crosscut saw [amzn.to/34ydmfb]
Shopping List:
Mantle [amzn.to/2KOsQnZ]
Epoxy [amzn.to/38muSE9]
Threaded rods [amzn.to/2KpZT1Z]
Tung oil [amzn.to/2KiOl0C]
Steps:
1. Measure approximately 55-56” off the floor, this is the average mantel height. Make sure the height is at least 12” above the top of the firebox, which is code.
2. Use joints of bricks to mark the center of the fireplace. Do not drill through the brick, it is more difficult and you risk damaging the brick. It will also be stronger to go through the mortar.
3. Find the center of the fireplace using the mortar lines.
4. From the center mark, measure out to the mortar line that is closest to 16” on each side.
5. Next, make sure all marks are level.
6. Drill pilot holes at each mark to make it easier to drill the larger bit.
7. Drill with the larger masonry bit and then clean out the dust and debris with a brush and/or vacuum.
8. Apply epoxy into the hole and insert the threaded rods.
9. Use 2x4’s to secure the rods and make sure they are level while the epoxy cures.
10. Cut the mantle down to the desired length. Use a circular saw or, like Nathan, a two-person crosscut saw to keep authenticity.
11. Use a block plane to clean up 5 of the 6 edges. The sixth edge is not needed as it will be against the wall. Cleaning up the beam will allow a smooth enough surface to apply a finish, without eliminating the marks from the axe.
12. Transfer the measurements from the wall onto the beam and drill.
13. Apply a finish to the five visible sides of the beam. A common finish for old wood was tung oil. It will not darken the beam too much and will help celebrate all the imperfections of the beam. Apply one coat to start and let set for about 15 minutes. Dry off with a lint-free rag. Focus on wiping the high glossy spots and the knots, as they don’t soak in the oil as well. If desired, apply a second coat in 24 hours.
14. Insert epoxy 3/4 of the way into the drilled holes of the beam.
15. Lift the mantle into place and push firmly onto the rods.
Resources:
The homeowner found the reclaimed beam at the Brimfield Antique Flea Market (brimfieldantiquefleamarket.com/ ), but materials like the beam can be found at most flea markets and also at reclaimed lumber yards. The two-person crosscut saw belonged to Nathan’s grandfather, but similar saws can also be found at flea markets and antique tool shops.
To secure the beam to the fireplace, Nathan used ⅝” threaded rods, which can be found at any home center, and Thixo 2:1 Epoxy System [amzn.to/34AkNlR], which is manufactured by TotalBoat (www.totalboat.com/ ).
The other tools and materials Nathan used to secure the mantel to the fireplace, including the drill, block plane, and sandpaper, can all be found at home centers.
Looking for more step by step guidance on how to complete projects around the house? Join This Old House Insider to stream over 1,000 episodes commercial-free: bit.ly/2GPiYbH
Plus, download our FREE app for full-episode streaming to your connected TV, phone or tablet: www.thisoldhouse.com/pages/st...
About Ask This Old House TV:
From the makers of This Old House, America’s first and most trusted home improvement show, Ask This Old House answers the steady stream of home improvement questions asked by viewers across the United States. Covering topics from landscaping to electrical to HVAC and plumbing to painting and more. Ask This Old House features the experts from This Old House, including general contractor Tom Silva, plumbing and heating expert Richard Trethewey, landscape contractor Jenn Nawada, master carpenter Norm Abram, and host Kevin O’Connor. Ask This Old House helps you protect and preserve your greatest investment-your home.
Follow This Old House and Ask This Old House:
Facebook: bit.ly/ThisOldHouseFB
Twitter: bit.ly/AskTOHTwitter
Pinterest: bit.ly/ThisOldHousePinterest
Instagram: bit.ly/AskTOHIG
How to Turn a Reclaimed Beam into a Fireplace Mantel | Ask This Old House
/ thisoldhouse

[@martinhamberger7633]

This gentleman needs to stick around for years just like Tommy he should be a staple to the program

[@bobby-c7731]

I really enjoy Nathan Gilbert. I want to see him become the next Tommy!

[@jlui21]

he looks like a younger version, just change the beard for a tommy-moustache and let cure for a couple of decades.

[@TotalBoat]

Perfect use of Thixo epoxy. Thanks, Nathan!

[@TheMixmastamike1000]

that looks amazing

[@heathdetweilerRealtor]

Gorgeous!

[@baspluim5925]

They cut off the video too soon, he only half-adzed that log

[@pufthemajicdragon]

Really good to see Nathan back on the show. This makes me excited for the future of TOH. I would have cut the mantel long so it extended wider than the chimney and cut out a groove to make it flush with both the chimney and the wall. Buuut that would've taken more than a day. I also would've used carriage bolts to attach it to the chimney so it could be removed - and antique bolts would've complimented the character of the wood.

[@derekw40]

Antique nuts ?

[@pufthemajicdragon]

@@derekw40 I mean, if you mount the bolts into the wall and then screw the mantle on with the nuts I guess. I was thinking the rounded head of the bolt would be what you left visible.

[@derekw40]

@@pufthemajicdragon oh I see. Thank you for clarifying. 😊

[@arth.4196]

Nathan good work, your a good addon to the show

[@bryansweeney4562]

Some mention of fireplace code would have been helpful. Min of 12" above the firebox opening.

[@toddcriswell796]

Glad you like it too because now you’re not getting that off without serious brick damage. Check out Toms video of securing a rail post to the floor. Same principle but removable.

[@heroknaderi]

Amazing 😉

[@KundelCrane]

check out our Restorer tool. It is designed specifically for reclaimed wood cleanup without destroying the character!

[@timskufca8039]

SUGGESTION: this is where an interior designer would have added a little finesse. The beam should have been situated with the surface of the mantel in the wide direction. Then it's calling out for a couple of corbels to act as a structural element. The way it was installed it looks fake - like you used epoxy to glue it in place (even though that's what was done, an old beam like this should at least look authentic).

[@justinwoods240]

I'm actually wanting to buy a draw knife i see another of those tools used today besides the two man saw

[@rheffner3]

Hey, that's on of the interns! Good for him!

[@glennriefenstahl3761]

Generation Next is working! Nice job Nathan. RIP Austin.

[@suehardie3183]

Just wondering what sort of instant nail Adhesive you use doing the same thing put on wood 🤔

[@mattlocke4680]

So whats the plan to remove the mantle when needed?

[@oogrooq]

Which one do you think is the 'top'. Either way, good for them.

[@liamarmstrong1836]

Just did my fireplace. New stacked stone and simple mahogany boxed out mantle with an oil finish. Wish I could have found a beam this guy got.

[@derekw40]

I have a couple from an 1800’s barn I used to own.

[@twdietri]

What would the size of hole in the masonry and threaded rod be?

[@joshuabennett723]

Is it just me or should it have been turned 90°s and had the long side on the top it just looks so wrong to me

[@twsbrl2xlldmoney355]

Rumor has it Nathan is still hueing and Guy is telling him thanks

[@quinnreid1209]

At the two person saw and block planning, it got a lil kat-moses

[@walkmen89]

hoorah seabee!

[@wenliu7875]

epoxy on ends, good luck removing it if you change your mind.

[@jeffwilson1399]

Epoxy on each end?!?!. . How do you remove the mantel if you need to at a later time? . . Sawrzall to cut the rod?

[@phonedave]

That was my thought. Do it like a stair rail, embed the rod in the masonry, and drill the holes in the beam. Then holes with a fostner bit from the bottom so you can secure it with nuts. You can even cut matching bungs from the end you cut off.

[@footnotedrummer]

Do you need to kiln dry these mantels to "sanitize" them from any pests that may be living in them?

[@paulkim1011]

Doesnt the mortar bed go horizontal?

[@MrKyleDD]

What was that finish he used?? 'Tongue oil'?

[@LadyUnderhill]

Tung oil. :)

[@surprisek3918]

How the hell is this mantle mounted??? All I saw was them sliding it onto the threaded rods? Did I miss something???

[@ericmichel3857]

The glue they put in the holes. It's an absurd way to mount because good luck if you need to take it down.

[@WILSON.1]

Great job, but unfortunately Nathan doesn't have the TV presence that the original characters of This Old House had.

[@lunchlady2023]

He doesn’t look like Tom Silva

[@trekabe9745]

Wheres Tommy and Kevin? Is this like a new one

[@krizm]

these guys seem like a party

[@dadylfitzys8880]

No reason to cut the wood. The overhang would have been good.

[@davidlamphier6319]

Four quick cuts with a circular saw and a speed square could have made the sawing process much easier. That two person saw would cost people more to acquire (if they don't already own one) than a corded skil saw.

[@pufthemajicdragon]

But you can tell the look of hand-sawn lumber and that's the whole point. The hand-sawing would've only taken a few minutes and dramatically improves the end result.

[@derekw40]

Way to really snub that guy try to show how to cleanup that log.

[@jakeschroeder1553]

The zoomed in, soft focus, slow-mo photography when they cut the beam is not a good look. Is this TOH or a truck commercial?

[@davidlamphier6319]

Please please please start correcting people when they say "masonary"... It takes more work for people to add the "A" than it does to say "masonry"...

[@smurfman691]

Yes... Such hard work!

[@jeffwilson1399]

Tha twoh lobstah sawr wahs dah rihht toohl fahr dah johb.🦞🦞🦞

[@shanew7361]

To each their own 🤮

[@ovidiuciuparu6421]

I can chop that wood with a normal axe! Just put it up vertically and is a lot easier! You never do that close to your legs!

[@dnthasslehoff]

That’s how you use an adze and when the timbers get large enough it’s the only way to do it, can’t stand up a 30’ log and square it with your ax, gotta stand on it and use the adze

[@markhall3323]

I don’t trust Nathan

[@scottwolverine3062]

soooooooooooo boring!!!!!!!! dude get some enthusiasm!!

[@mitchellb.9877]

Unreal how new producers have thoroughly messed up this show. It’s no longer authentic, entirely too scripted, and no longer entertaining. Like Bob Villa alluded to when he left...you became too Hollywood, TOH. Sad to see.

[@johnlebzelter4208]

Yet you still watch/comment on vids

[@hswrestlr]

That lisp though.

[@ashtonjhugh]

So what if he has a lisp. It has nothing to do with anything.