Monday, July 21, 2014

DIY Faux Fireplace Entertainment Center: Part One

Hi y'all!  I hope you had a marvelous weekend.  Ours was a busy one, and I'm crazy STOKED about sharing with you my favorite (and biggest) project to date.  When we moved in to our builder-grade-basic cookie cutter house 7 months ago, we immediately started pining for a fireplace.  (Considering we moved in a week before Christmas and didn't have a mantle for our stockings, that might explain it.)  The builder would have charged $5,000 for one and we just couldn't swing that in our budget.  We got the crazy idea to build a faux fireplace, but we wanted it to be more than a simple mantel nailed to the wall.  This idea was big.  REALLY big.  So big in fact that I'm having to split this project up into 3 posts.  Woo hoo!  So stick with me.  What you see today is only a glimpse of the beginning stages, and I'll show you every step of the process for under $500!  So much better without that extra zero, isn't it?  Even if it is a faux one for now.

Update: Check out Part Two and Part Three!



Just last week, we were living with this situation (which I already whined to you about before):


Those shelves were a constant battle with Olivia who made it her daily job to completely dump all of the DVD cases onto the floor.  Ugh!  So we trucked those two bookcases up to the office, and we were left with this:


Yep.  We're starting from scratch, people.  Well...mostly anyway.  Several months ago, we found this beautiful mantel from a house being demolished in Charlotte.  Robert thought the seller said it was built in 1916.  I heard 1940.  Either way, this thing has some history.  

And my ingenious father-in-law came over to help us through the entire process (that took all weekend long...this man deserves a lollipop.)  I mainly shadowed his and Robert's work and shoved a camera in their faces half the time.

For this part one glimpse of the fireplace, here are the materials we used:
The ready-made mantel front (found for $100 on Craigslist)
3 plywood sheets
9 2x4 boards
Carpentry nails
Finishing nails
Drywall screws
Tape measure
Circular saw
Jigsaw
Piano hinge
Hammer
Power drill
Hack saw

First thing we did was find the center of the wall and decide on the measurements based on the existing mantel front.


We chose not to have Lowe's pre-cut our wood in case we needed to make any adjustments during the process.  So Robert got to be all manly with his circular saw.  (Right after this shot, he remembered his safety glasses.  Safety first, peeps!)


To frame out the base of the hearth, we cut two long 2x4s about 8 inches longer than the mantel and connected them with shorter 2x4 pieces at 24 inches long.  Nail the long sides to the end pieces first, followed by the center piece, and the other two middle pieces last.  (The diagram below can show you.)


Once the hearth base frame was secure, we lined it up to the center of the wall and nailed the back of the frame to anchor it to the wall.  We had thought about cutting a couple of holes in the carpet underneath to anchor it to the floor but decided it wouldn't be necessary with all of the weight of the fireplace itself.  This sucker is heavy and that hearth isn't going ANYWHERE.  If we ever decide to rip up the carpet one day and put in wood floors, it can be done with a box cutter and quarter round at the base of the hearth.  


To cut the plywood pieces, Robert's dad schooled us on a bit of  woodworking knowledge, which he has TONS of.  One of his tips was to cut a piece of plywood using a circular saw in a shallow position.


From the plywood sheet, Robert cut out the piece for the top of the hearth.  


Then, we (and by we I mean they) layed it out on the hearth frame.  It lined up perfectly!  


Then nailed the hearth top into the frame base.


For the mantel, we nailed in 2x4s inside the back of the frame to later use as an anchor to the wall.



Then, we nailed up 2x4s at the same height as the mantel back.


Here is the hearth and wall anchor ready for the mantel:



Olivia thought it was her own personal stage, so she put on a little show for us during our break.  So stinkin' cute!


Then we cut plywood strips to screw onto the back of the mantel to anchor the surround that would come next.


We used a piece of plywood over the mantel opening to make into the surround.



We used drywall screws to fasten the plywood to the anchor strips from the previous step.


Here's where our faux fireplace becomes a bit more than a faux fireplace.  We wanted this space to still be useful, so we put in a door to fake a firebox and have access to our outlet to run our cords out of sight.  We measured the faux firebox door and left a little space at the bottom to create a threshold and prevent the surround from bowing.


We switched circular saw blades to cut out the door to one that was thin and would be precise.


My father-in-law did the honors of this part. :)


For the corners, he used a jigsaw to make sure each cut was exact.


It's looking more and more like a real fireplace!  (Robert is excited too in case you couldn't tell.)


To create the firebox door, we screwed a piano hinge into the surround piece.  We cut it to size first using a hack saw.


To make sure the door wouldn't cause any bowing or movement in the surround, we made a door frame on the back of the mantel.


We shaved off just a teeny tiny bit of the door, and it fit like a glove once attached to the piano hinge!


To anchor the mantel to the wall (the big oooh ahhh moment...well the first one anyway), we nailed plywood strips to the 2x4s we had previously attached to the wall and back of the mantel.  We nailed the bottom piece under the door to a 2x4 attached to the hearth inside of the firebox but somehow I forgot to photograph that step.  Sorry, y'all. :-/




After the two plywood sidepieces were up, this is what the top looked like:


To close in the top, we added a plywood piece and attached it to the 2x4s on the mantel and wall as well as the plywood side pieces.  That thing was going no where!


We laid down one more plywood piece on the top and mimicked the end molding of the mantel shelf.  Robert secured it with finishing nails.


And then helloooo fireplace!


I know it still looks rough here, but we are nowhere close to finished.  We have much more done already, but for now you'll have to live with the anticipation as I unveil this puppy in a couple more posts this week.  (So subscribe if you'd like to keep up with the progress!)

What we have left after this step:
Build a "faux chimney" plank wall up to the ceiling
Prime and paint
Add airstone to front, sides, and hearth
Whitewash airstone to look like distressed brick
Paint door a flat black
Add cut log rounds to attach to door to look like stacked logs inside firebox
Hang television and run wiring for DVD player and playstation (hence the entertainment center title)
Style our pretty new mantel!

One day, we might muster up the funds to have a real gas firebox insert put in, but we're excited about the versatility of our setup.

Until my next update, have a great week!  What are your thoughts on it so far?  Have any of you built a faux fireplace before or have a hankering to?



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17 comments:

  1. Oh wow, I can't wait to see how this looks when it's done. I loooooove the mantel!

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  2. Oh wow! I can't wait to see how it looks when it's finished. LOVE the mantel!

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  3. I love this!!! I so want to do this in my house though I am not sure where I would put it right now....LOL If you would Iike, know my readers would LOVE this DIY, you are welcome to link up at my link party Tuesday's with a Twist. I would love to see this there so my readers can enjoy this as well. :-)

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    1. Thanks for letting me know! I'm always up for a good link party. I'll be there. :)

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  4. Lauren what a great addition to your living room! Can't wait to see it completed.

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    1. Thanks Pamela! I can't wait to show you the big reveal!

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  5. That looks wonderful! and I am loving the stage performer too, she is a doll!

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    1. Thanks, Christine! I think the stage performance was our hint that ballet classes are in our future. :)

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  6. You designed a beautiful fireplace......... I just found your blog........love it.............I am your newest follower.

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    1. Woo hoo! *Insert new follower celebratory booty dance* Thanks, Susan. :)

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  7. I am so excited about your new "fireplace" and happy to hear you had a performance stage for a while.... What a great idea! :)
    xox, Crystelle
    CrystelleBoutique

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    1. Thanks! I'm excited to share the final reveal!

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  8. Oh my gosh, it looks awesome! I can't wait to see the finished product! My favorite post yet!

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  9. this is so great. I can't wait to see all the steps so I can convince husband he should do this in our bedroom

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  10. This is absolutely phenomenal! Thank you so much for sharing at Project Inspire{d}, Lauren. This will be one of my features for this week's party. I hope to see you there!

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    1. Thanks so much, Mary Beth! I just linked up my update on it. :)

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