Here at Reclaimed World, we specialise in crafting and selling stunning wooden mantel beams, and we’re excited to share the secrets behind how we make them. The mantel beams we make on site are very popular with customers, as we have a wide selection that are ready to mount straight on to your fireplace. In this guide, we’ll walk you step by step through the process of selecting, preparing, finishing, and installing your wooden mantel beam.
As a reclamation yard, we’re lucky to work with an array of old, rustic beams, each with its own unique charm. There’s something truly magical about these time-worn pieces. This guide will help you transform a beam into something special. If you’d prefer to skip the hard work, you’re always welcome to purchase one of our fully finished beams.
A Complete Guide to Crafting and Installing Wooden Mantel Beams
Step One: Selecting a Suitable Beach
Start by checking the condition of your beam. Look for signs of rot or damage, and ensure the beam is solid throughout. If woodworm is present, treat it first. Be sure to address any loose or decayed sections by removing them with a draw knife, leaving only solid wood. This ensures your beam is structurally sound before moving forward.
Step Two: Cutting the Beam to Size
The next step is to cut the beam to the correct size for your project. This step can be done in a variety of ways depending on the size and type of beam you’re working with:
Measure the space where your beam will sit and cut the beam to the appropriate length. For smaller beams, a hand saw provides precision, while power tools like a circular saw or chainsaw are better for larger beams. If you have a mitre saw, this is an excellent tool for clean cuts. Always double-check your measurements to ensure the beam fits perfectly in the space.
Step Three: Sanding the Beam
Use coarse-grit sandpaper to remove rough areas and prepare the wood for treatment. This step doesn’t need to achieve a perfectly smooth finish but should ensure the beam is free of any loose bits and rough patches. Sand evenly across the surface to expose the wood’s pores, which will help treatments and finishes adhere better.
Step Four: Treating the Wood
After sanding, treat the beam for woodworm, if necessary. Apply a suitable treatment product according to the manufacturer’s instructions. These typically come as sprays or brush-on treatments. Once applied, let the beam dry thoroughly, which could take 24-48 hours. Woodworm damage can be superficial, but if extensive, the beam may become brittle, and you might need to replace it.
Step Five: Sanding
Once the treatment has dried, move on to finer sanding. Start with medium-grit (80-120) sandpaper to smooth out any inconsistencies, then move to fine-grit (180-220) sandpaper for a smooth, polished finish. Sand in the direction of the grain to avoid scratches and achieve a clean, even finish. Remember to clean the surface regularly to remove dust, so you can assess the wood’s true texture.
Step Six: Sealing the beam
To protect and enhance the beauty of your beam, apply a finish. A wax finish is ideal for bringing out the natural grain of reclaimed wood and adding a warm sheen. Follow the manufacturer’s guidelines for application. Typically, you’ll apply in thin, even layers, allowing for adequate drying time between coats. Buff the surface after the final coat for a smooth, polished look. The finish not only enhances the appearance but also protects the beam against dust and moisture.’
Mounting Your Finished Beam
Whether you’ve crafted your very own beam or purchased a finished one from us, the final step is to install it in its rightful place.
Step One: Measuring and Marking the Wall
Measure and mark the desired height on the wall using a spirit level to ensure the beam sits straight. Take into account any furniture or decor below the mantel.
Step Two: Marking and Preparing Bracket Locations
For solid walls, mark the positions of the brackets 6 inches from each end of the beam, with one bracket every foot. This ensures even weight distribution. On stud walls, locate the studs behind the plasterboard to secure the brackets properly.
Step Three: Attaching the Brackets
Drill holes in the wall, insert raw plugs, and attach the brackets securely. Leave slight adjustability for final alignment, and consider using washers to distribute weight more evenly.
Step Four: Preparing the Beam
Mark the vertical centre of the beam and drill corresponding holes to align with the brackets. Ensure these holes are deep enough to securely fit the brackets.
Step Five: Installing the Beam
Slide the beam onto the brackets, adjust it to ensure it’s level, and push it flush against the wall for a firm fit. Tighten everything in place, and your beam is securely mounted.
Completion and Maintenance
Once the beam is in place, all that’s left is to enjoy the warmth and charm it adds to your space. Regularly dust the beam with a soft cloth, and reapply your finish every so often to maintain its beauty and protect it for years to come.
