Mantel with glass door cabinet above

[mbcabinetmaker]

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I have prepared the stock for the legs. They will be 5 inches wide and made up in sections. The center sections will be fluted. The piece to the right is for the plinth block on the upper cabinet. We will get to it later.






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I have set up my Williams Hussey machine with a knife that cuts 4 flutes at one time.






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This is the stock going in.






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This is the fluted board coming out.

[mbcabinetmaker]

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I will use pocket screw joinery for the legs.






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A little glue to help with the holding.






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This works good when clamped to the edge of a work bench. I have a special ledge on mine just for working with pocket screws and face frames.






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A view from the face side.






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The legs are ready for the drum sander.

[mbcabinetmaker]

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I have retrieved the breast plate and will sand it and the legs at the same time.








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There is some nasty looking saw marks on the legs that we need to remove before proceeding.









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My preferred method for this operation is a sharp block plane.










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Those are some really white shavings.

[mbcabinetmaker]

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We will join the legs and breast plate with dominos.








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While this is tacking up I need to run some crown molding, two types of base cap and some edge molding.








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3 1/2 inch crown








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This is the way that I remove saw marks from stock under 3 inches wide. I just gang up 2 or 3 pieces and run them through the planer on each side. I take off 1/16" per pass so if I want 1 1/2" inch finished stock I'll rip it 1 5/8" wide.

[mbcabinetmaker]

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Our next step is to build the mantle body out the depth of the marble from the sheetrock. The marble measures 1 3/8" so I have prepared some 1 1/2" strips to attach to the back of the legs.








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Now we have the body of the mantle ready to sand and figure out the shelf.








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All sanded up.








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This 3 1/2" crown projects out 2". The edge molding starts there and projects an additional 3/4". I want the mantle shelf to be 8 inches deep. I will cut two pieces of plywood 7 1/4" and 4 inches longer than the mantle body or 61 1/2".

[mbcabinetmaker]

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I have attached the first piece of plywood with brads and screws. Notice that it hangs over by 2 inches on each end. This is the amount that the crown molding projects. I will glue the second piece of plywood to the first one and attach it with brads. This will create the very top of the mantle. The edge molding is 1 1/2" tall and will cover the plywood grain.








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The next step is to determine the bottom of the crown molding. By bedding a piece and measuring the height I have concluded that it is 2 7/8" tall. We will need a piece of plywood at that location that is 2 inches less that the 7 1/4" top pieces. We also have to deduct the depth of the mantle body which is 2 1/4". This piece comes out to 3" and is the length of the mantle body. I have attached it with a spacer of 2 1/8" to give us the 2 7/8" required in height.








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The next step is to wrap the crown molding.








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Final step in finishing the shelf is to wrap the edge molding around the 2 layers of plywood fill all nail holes and sand when dry.

[dlbristol]

WOW! Not much I can say. Thank you for sharing.

[JPG]

Were the pilaster shelf supports deleted by the 'customer'?

[mbcabinetmaker]

JPG the supports or corbels have not been decided upon. I have designed it for this corbel [ATTACH]10049[/ATTACH] but it will be decided upon after installation.

[JPG]

JPG the supports or corbels have not been decided upon. I have designed it for this corbel [ATTACH]10049[/ATTACH] but it will be decided upon after installation.

Knew 'corbel' was applicable to masonry, did not realize it was correct term here.

Pay attention, learning is there if you be observant(and ask the relevant question)! Thanks!