Step 1:
Cut plywood down to desired size to create base. Our overall size is 48"
wide x 28" high.
Step 2:
Cut the beaded board down to the exact size of the plywood. Match the
edges, and attach with wood glue. Clamp until dry.
Step 3:
Draw a line across the board 7" from the bottom on the front and
back sides.
Step 4:
Cut down the 1 x 6 board to 48" long to be used for the shelf.
Step 5:
Drill pilot holes for #10 wood screws every 6" along the line on
the back of the plywood.
Step 6:
Apply wood glue across the edge of the shelf board, and attach to base,
centering on the line.
Step 7:
Holding the shelf board centered on the line, attach with screws from
the back into the edge of the board.
Step 8:
Miter the outer edge, and affix smaller crown moulding to the front and
edge of the shelf board.
Step 9:
Miter the outer edge, and attach larger crown moulding to the top of the
main board.
Step 10:
Apply stain
and polyurethane to the whole mantel shelf, and use some of the same
techniques suggested for aging the bench.
Step 11:
Once you reach your desired finish, drill five holes for the hardware
to attach knobs below the shelf.
Step 12:
Attach two D-rings on the back side of the mantel shelf as hangers and
use 100-pound hangers to secure it to the wall.
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