Shannon Berrey

Scrap Wood Fireplace: Part 2

Wednesday, June 20, 2012

Yesterday, I explained how we created the wood surround on our fireplace. Today I'll show you how we added the mantle and the wall above. 

We decided to leave the ledge that was already there {it has the green edge}. This is where the TV sat originally.

Cutting a 2x4 on a 45, we secured it to the top of the ledge to begin the framing process.

The framing is critical because it is what supports the weight of the heavy TV. If it's not secure, then the TV could come crashing down. bad. We are not framers, but we secured it at every possible angle.

Ours are 16" on center. 

We framed an opening that would allow us to access the plug and electrical components in the back. 

 We cut a piece of sheetrock. Sheetrock comes in sheets of 4'x8'. We turned it on it's side and it was a few inches short across the bottom--not a problem. We attached it with screws to the studs.

 The opening in the sheetrock was cut out with the oscillating tool. 

With the leftover piece of the sheetrock, we added a little piece on each side because the wall is exposed on the very edges of the mantle. I used joint compound to fill the space where the sheetrock touches the wall.

 To attach the mantle, we cut a 2x4 in half, lengthwise, and attached them 5" apart, making sure it was level.


 We slipped the bottom edge of the mantle, which is a primed 1x6, on it's side. Using the pneumatic nailer, we attached it to the 2x4 from the underside. It sits right on top of the top row of scrap wood. Because I was so crazy about being level with the scrap wood application, the mantle sits perfectly level with no gap. Yea!   

 Then the front of the mantle, a 1x6 that we cut down to a 1x5, was attached to the front using the nailer. This piece covers up our seam where the sheetrock ends.

The top of the mantle was attached from above. Using a piece of 1x3, we mitered the edges and attached it to the edges of the sheetrock with the nailer. Everything was painted, sanded and caulked. The finished mantle is 6 1/2" tall.

We attached the hanging mechanism for flat screen TV's { We bought ours off Amazon--the low-profile Sanus} to the back of the TV following the manufacturers directions.


 The TV slid on from the top.








Scrap Wood Fireplace: Part 1

Tuesday, June 19, 2012

Yesterday I shared my fireplace as it appeared a few weeks ago. Now you can see it New and Improved!

{Please disregard the rainbow hearth--we haven't decided on a tile yet so there are a few different ones pictured}

Using our inspiration picture:

I contacted a local company that sells vintage board and beams. I explained that we just wanted scrap old wood and showed him a picture of what we wanted to do. As usual, I got a cocked head and a very puzzled look from said man. It's OK, I'm used to it. 


 He showed us a stack of junk wood and told us we were welcome to as much as we needed. Score!


We loaded up the van and stacked them in the garage. They needed to dry out a little and after a few days we sprayed them with Ant and Roach killer because they had lots of ants and you don't want any of those guys coming to live with you. 

Robert then used the table saw to rip the boards to varying thicknesses -- 1 1/2"-2" in thickness. Then he used an orbital sander to lightly sand the front surface. If you sand too much, you lose all the wonderful dings and gray spots that go along with being wonderfully old and all the stories that it holds! if only we felt that way about our own aging....sigh...

This is what I then had to work with. {see my cute assistant in the top left corner?}

A little side note -- I planned on simply cutting the boards into random lengths and then fitting it together as I went. Robert suggested that I cut each row to the exact length needed and recreate it on the garage floor to get a look at the overall project before it was installed. If I had done it my way, we would have ended up with a ton of scraps and probably not enough good pieces. Good. Call. Robbie Ray!

I wanted it to consist of many different depths and widths so I puzzled it together accordingly.




Then it was time to add the stain. I used Minwax Gel stain. I had around 7 different stain colors left over from other projects that I sampled. I decided on Aged Oak.

 I like using the Gel stain because it gives me a little more control and I’m a control freak and is less messy than regular stain. I picked up each board and applied the stain with a rag on the front, the edges and half way back on the top and bottom edges. Because they are staggering depths, you see different parts of each.  

This is with one coat.

After an hour, the stain had really sunk in and had lightened quite a bit. I felt there were lots of places that needed more stain, so I decided to give everything a 2nd coat,

I loved the way it looked after 2 coats. {Staining was the longest part of the whole process}

I didn't stain the top several rows because these were extras for just in case    .


 Before I started to attach the wood, I wanted to cut off the top of the sheetrock. This would be the seam where the new piece of sheetrock would be attached. It would be hidden behind the mantle. I was afraid that the wood might interfere with my cutting if I waited to do this step. We measured down 7" and used a laser level to draw the line.

Using an oscillating tool, I cut through the sheetrock along my line, like butta.

We then removed the strip of sheetrock, exposing the studs. Ours were 16" on center. 

I gathered the supplies for installing the wood: level, construction adhesive, crowbar, pneumatic nailer, nailset, hammer, tape measure {not pictured is the air compressor}

We brought the wood 'puzzle' up and laid it out on the floor in front of the fireplace, making sure to keep it in the exact order it was in in the garage.

I used some wood on the floor to act as spacers at the very bottom to allow for me to slide my tile and backer board in {when I find it} and began gluing the strips of wood. Ideally, the hearth would go in first but I still haven't found one, so this was Option 2.

The white paint on the right shows where the old surround ended. Notice that I chose to extend the new one all the way to the corner.


After applying the adhesive and attaching each row on the wall, I used a level to make sure it was, well...level. Listen kids, it's super important that every row is level!! Other wise you will get to the top and it will be really be all whomperjawed and everytime you are sitting there watching The Real Housewives you won't even be able to concentrate because looking at your crooked wood will have you feeling tipsy. Trust.

Then I used the nailer to shoot nails in on the sides, at an angle, to make sure they were not going anywhere. I made sure that each row lined up perfectly on the outside edges. Tip: if a nail didn't shoot in all the way, I used a nail set and a hammer to tap it down. If you leave it sticking up, it can throw your level on the next row. And you want it level {see above} 

Some places I had to use shims to make sure it was level. {'Shims' as in: folded pieces of paper, coasters, a piece of cardboard--whatever I could find} The piece in the middle, across the top of the firebox, was supported by a piece of wood that propped it up until the glue dried.

  In all it's wooden glory!!  Tomorrow I'll show you how we made the mantle, framed the new wall above  and hung the TV.  

The Fireplace redo: Before

Monday, June 18, 2012

When we moved into our new home 5+ years ago, there were things we wanted to redo immediately and things that would get redone in time. One of the areas that we felt was on the back burner was the fireplace.


Not horrible, but I knew it could be better. I really don't prefer a corner fireplace {on a porch I don't mind so much}, but that could not be changed. Every client I have worked with that is building a new home, has requested a stone fireplace. It's rustic and lends itself perfectly to our mountains. 

I also don't mind faux stone. I really like the kind that I used around my kitchen island. But, like in most everything, there is good faux and there is bad faux. What I had around my fireplace was a faux stone facade. It was literally a bunch of thin peachy colored faux stone that was glued too far apart onto a piece of plywood. The plywood was screwed onto the drywall. From the sides, you could easily see the edge of the plywood. Yuck.


I had enough stone left over from my island project that I could remove my facade and redo the fireplace with it. I really have always thought that this is what I would do, when I could find the time to do it. But, to be honest, after overseeing the intall of so many stone fireplaces throughout the years, recently, I decided that I really wanted something different in my house.

I loved the patinaed metal surround that we did in the Clubhouse at Bear Lake Reserve. But, I am a bit too traditional in my decorating to make this feel right in my own home.  

Then I saw this picture of a salvaged wood wall that was featured at Apartment Therapy many years back. Bingo!!

I went to the source-lumberjocks to gain info on how he created this. He explained that he attached his wood to the wall with a hot glue gun {??!!} I knew that I would have to tweak this application to use around a hot fireplace. But we were up for the task!

Tomorrow I will show you our finished fireplace!


I have been invited over to The Painted Home today to show you the innards of my Beach Bag. If you would like a closer look, please jump over and visit.

Father's Day printables

Friday, June 15, 2012

Well, here we are, the end of another week! Somehow the fact that Father's Day is this Sunday has snuck up on me. If you are in the same boat, no worries, the nice gals over at Hello!Lucky have got us covered!

They provide the links to download these fun labels. Just print and you have yourself a special label to add to a pair of socks, a bottle of wine or his favorite brew.


There are a few more to choose from so visit their blog and start printing.

Shannon Berrey Bio
I'm an artist, interior designer, wife and mom. Join me here as I share projects, ramblings, and inspirations.
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