DIY Mantel

metalspinner · January 30, 2008, 12:59:52 PM

I have been asked to build a mantel and fireplace surround for a segment on the Do-It-Yourself Network. This will be a one minute segment sponsored by Sears and their Compucarve machine. Here is a thread discussing the tool...

https://forestryforum.com/board/index.php/topic,23372.0.html

Here is a sketch of the mantel and surround I came up with...

Sorry about the poor quality of the drawing and scanning. I hope to cut the wood better than I can draw it. :-[

The little sketch to the left is a profile of the pedestals. I will basically just build a three sided box to slip over a wall cleat (the existing surround). A bull nose molding will be applied to the edge's of these columns.

The squiggly lines in the fields of the columns will be applied carvings from the Compucarve.

The bold short vertical pieces at the top of the sketch will be corbels.

The homeowner wanted mahogany. Can you believe it. I have been sawing and collecting cherry and walnut pieces for just such an occasion and they want mahogany. :-\ Well I just returned from buying the needed materials and -

- that stuff ain't cheap! The dealer had what he called "shop mahogany" plywood which is a regular sheet of ribbon stripe that came in with a blemish. That dropped the price from $96 to $85.

He did not have 16/4 in stock for the mantel and could not tell me how long delivery would be. So after poking around a bit I came across a piece of 16/4 Spanish Cedar. At $7 BF, that was less than laminating 8/4 mahogany and the color was spot on so I went with that. That visit reminded me of why I collect my own logs and hire you guys to saw for me. I'm glad I don't have to visit the lumber dealer too often.

Time to get busy in the shop...

Pics to follow later.

Dodgy Loner · January 30, 2008, 02:04:28 PM

Sounds like a fun job. Let us know when it airs, so we can set up the DVR

!

SwampDonkey · January 30, 2008, 07:13:31 PM

Good deal. Don't worry about the drawing, it's only meant to mean something to the artist. ;) I don't see Sears adds here to often. Maybe a Youtube will show up. ;D

You use fancy terms like corbel that I had to look up. ;D Use the walnut and just call it American mahogany. I'm sure the term has been coined and used by others already. To some people it's just a name and they wouldn't know the difference. Shame on me for suggesting such a thing. ;)

WDH · January 30, 2008, 09:38:01 PM

Looks like a challenging project ;D. I eagerly await all details of the process.

metalspinner · January 30, 2008, 11:22:05 PM

QuoteDon't worry about the drawing, it's only meant to mean something to the artist.

This is the most detailed drawing I've ever done. Usually I design on the fly. But this project is away from the house and I had to show the homeowner something.

QuoteYou use fancy terms like corbel that I had to look up.

I'm using fancy wood, I should use fancy language. ;) Besides that sounded better than "that curvy thing holding the mantel up." :D

Here are a couple of pics...

Part of the fancy sheet of plywood...

The three box frames that make up the structure to the surround. They are held together with glue and pocket screws...

Well, That pic didn't turn out to good. :-\

The box in the clamps is the horizontal member that spans across the fireplace. The box next to it is the backside of a vertical member.

And the three boxes assembled...

All those colors in that room just blend together, don't they? :D Sorry about that. That room is right next to the shop and is under construction. It gave me a place to spread out and assemble this project.

This framework went together pretty quick. I need to start dressing it up with mouldings and carvings now. I am still trying to get a better grasp of the Compucarve software. It will do what I ask, but what I am asking just doesn't look to good. :-\

WDH · January 30, 2008, 11:27:04 PM

Wow!! That looks good 8).

SwampDonkey · January 31, 2008, 07:19:18 AM

Now don't destroy that nice wood with that Dang Sears Compucarve. :D :D :D ;D

Fla._Deadheader · January 31, 2008, 01:38:00 PM

How ya liking that Cedro Amargo (Spanish Cedar) :

??? ;D ;D

metalspinner · February 25, 2008, 10:53:31 PM

It's been a while...sorry.

After a bout with the flu bug, then debugging the Compucarve, I finally got this project completed.

Here is a pic of the mantel installed...

This is one of those projects that left me wondering, "What have I gotten myself into?" :-\

The woodworking and design was no trouble and quite enjoyable. I had never made a surround and mantel before, so I looked forward to doing that work. But the added responsibility of using the Compucarve really frustrated this project. The first machine they sent out for me to use turned out to be a dud. This was only discovered after many days worth of work and many hours spent with tech support on the phone. The shoot date was postponed three times because the machine kept breaking down. Getting into the many idiosyncrasies of this machine will take up to much server space and Jeff might delete the post. :D Finally, a new redesigned tool was sent out and worked as advertised which brought this project to an end.

I do have to say that the customer service support from Carvewright is top notch. Everytime I called with an error code they were right there to help me diagnose the issue. The tech support staff really know the machine and helped to resolve the issues with great patience. The websight has a forum that members contribute to. Unfortunately, I could never find exactly what was wrong with my particular machine through the search function.

The carvings themselves are pretty rough right out of the machine. Compressing the images too much in the software is not advisable. The carving bit is a 1/16" spiral bit, so fine details get lost in tear out of the endgrain. The center carvings - excluding the "R" - took about 2hrs and 15 min. Each of the upright carvings took about 2.5 hrs. This did not include material prep time, nor releasing the carving from the board to be used as an applique. Also, considerable time was spent on each carving element cleaning up the rough surface.

The day of the shoot went well. Installation was fairly easy, but was stop and go because of the whole "on camera" thing. Why shoot it once when you can shoot it ten times. :

Also, the home owner was there and kept chirping in with concerns. Like, "I thought the wood was going to be darker." "It does not have a finish on it yet. It will darken considerably when I oil it," I replied. Then an hour later, "are you sure it is going to darken. It sure looks pretty light to me." On and on with this sort of thing all day. :

It ended up being a 13 hr day. I'm not sure when the rough cut of the spot will be ready, but it usually does not take too long. Maybe this week.

One funny thing happened that evening when they were taking the final "beauty shot." This was at about 9:30. The flatscreen on top of the mantel was on the DIY Network and a fire was flickering in the fireplace when a commercial for the Compucarve happened to come on. Of course, the tool performed perfectly and within seconds a flawless carving spits out of the machine. The producer just about threw a camera into the TV at that point.

Don K · February 26, 2008, 04:08:35 AM

Very nice work Chris. You are much braver than I am. I can't wait to see the segment. I can tell my family that " I met Chris before he was a star." ;D I imagine it was a relief to drive away that night. You didn't get a speeding ticket did you? ??? :D

Don

SwampDonkey · February 26, 2008, 06:46:39 AM

Looks nice from where I'm sitting. ;D So, you got your Compucarve on order? ;)

I think I would have lost it long before the 13 hours. Some people can bring a preacher out of religion. :

WDH · February 26, 2008, 11:19:18 PM

Now, that is fine!!!! 8). You inspire me ;D.

scsmith42 · February 27, 2008, 01:54:25 AM

Chris - that is way cool! Man, two media stars in one day (you and Arky); y'all will probably have to sign lots of autographs at the pig roast! :D

metalspinner · February 27, 2008, 08:22:25 AM

:D Thanks, Guy's.

You won't think I was much of a star after this... :D

One part of the shoot, I was to retrieve a bundle of firewood from the trailer to bring inside. How hard is that, right??? Well, after the seventh or eighth time of them recording me picking up a bundle and walking away they finally decided I got it right. :

Apparently I didn't look relaxed or natural enough. :

How hard is it to grab a bundle and walk away? :-[ :D

flip · February 27, 2008, 08:53:16 AM

Excellent work MS. Looks like the hobby is going to start becomming a bid ness. A little air time is always good 8) 8)

metalspinner · February 27, 2008, 10:32:32 AM

QuoteLooks like the hobby is going to start becomming a bid ness.

Ya know, I think there could be good money in building quality surrounds and mantels. Think about all the McMansions being put up. Each one of them has a paint grade surround. Aside from the carvings on this project, the mantel and surround can be fabbed in one day and installed in half of another. Depending on your materials cost (large, thick mantel and a bit of 8/4) these can be constructed rather inexpensively. Sawmill owners have a leg up in the materials department.

This is a before shot of the surround...

Blech...

flip · February 27, 2008, 10:47:40 AM

Looks like about $150 in box store trim, $1200 in labor and $300 in primer and paint :

:

Got to love it ;)

Patty · February 27, 2008, 03:09:07 PM

MS, you did a great job. The new mantel is beautiful.

getoverit · March 16, 2008, 02:27:09 AM

Nice looking woodwork Metalspinner!

I wanted a CNC machine and when I saw the compucarve ad's I thought I had found it. Someone mentioned that I should go tot he compucarve website and read the trouble reports before I bought one and I am glad I did. Needless to say, I didnt buy one of those but bought a real CNC machine instead.

Great job with the mantle!