Build Series - Fireplace Mantel

Transform your Space

Built By Hand Fireplace Mantel Surround

A fireplace mantel is more than just a functional element - it's the centerpiece of your living room, a place to showcase your style, and a cozy hub for gatherings. Building your own mantel surround saves money and allows you to create a truly personalized design that suits your space and aesthetic. This guide will show you how to build a custom fireplace mantel surround using Festool tools, which are known for their efficiency and precision - perfect even for small home workshops.

Skill Level:This project is best suited for those with an intermediate level of woodworking experience. Comfort and familiarity with power tools and woodworking techniques are essential.

Materials Needed:

  • Poplar - approximately 13 board feet of 6/4 poplar in varying widths for the column base and the mantel top and approximately 2 board feet of 3/4 poplar for the medallion and the arch.
  • Birch plywood - approximately 2 sheets of Birch plywood or a comparable material for the structure of the mantel surround.

Watch this step-by-step video.

To download project plans, create an account or log into MyFestool.
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Tips and Tricks to Consider:

  1. For repeatable and accurate tapers, you can use the FS-WA angle unit in conjunction with the TS 60.

  2. When prepping for a dry fit, sand the long edges of the DOMINO tenon down for easier assembly and then use unsanded tenons for the final glue-up.

  3. Use the DF 500's adjustable width setting to make the assembly process easier. Set only one mortise to the tight setting and all others to the second loose setting. This will allow the first mortise to be your alignment mortise and give room to all of the other mortises for easier assembly.

  4. ALWAYS ensure the DF 500 is running when you change the mortise width setting.

  5. Utilize any of the FS guide rails as a reference point for the DF 500 to keep a long line of mortise in line.

  6. A key principle to remember when using track saws is that the material beneath the guide rail is the part you want to keep. This understanding eliminates any confusion about the blade kerf and ensures accurate cuts every time.
Brent using a TS 60 track saw to cut

Tools used in this project

To bring this project to life, Brent used various Festool products along with some additional hand tools.

The products have been added to the wish list.

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