How to Build a Rustic Stone Fireplace

Rustic stone fireplaces add warmth and a country feel to a room regardless of whether you live in downtown Manhattan or in the middle of the Colorado wilderness. However, having a contractor build a stone fireplace for you can be pricey and often requires the loss of the use of that room for a week or more. You can avoid the expense and inconvenience of working with a contractor by building the fireplace yourself.

Difficulty: Moderately Challenging

Instructions

Things You'll Need:

• Rustic stones Mortar Barrel mortar mixer Trowel Plywood 2 by 4 lumber 3-inch lag bolts 1 by 8 lumber Commercially produced hearth stone

1. Design and construct the frame and layout of your fireplace with the plywood and 2 by 4 lumber. Determine where you can tie into your existing chimney and how large you want your fireplace and hearth to be. Cut a section of plywood that will fit around the existing fireplace hole and then use the 2 by 4s to build a solid square frame behind the plywood. Use the lag bolts to secure the frame to the existing fireplace wall.

2. Fill the mortar barrel up with the manufacturer's recommended amount of water and mortar and then roll it around the yard until the mortar has reached the proper consistency (according to the mortar package). Use the trowel to spread mortar onto the back of the the stones and place them onto the plywood faceplate, starting at the bottom. Try to pick stones that appear to fit together, kind of like puzzle pieces. After securing the stones to the plywood, allow to dry completely.

3. Mix up more mortar according to the manufacturer's instructions and fill in the spaces between stones with the extra mortar. You want to cover up all of the visible wood to give the illusion of solid stone. Make a mantel by cutting a piece of the 1 by 8 lumber to be 6 inches longer than the top width of your fireplace. Center the wood on top of the fireplace and then mount with the lag bolts. You can also stain the wood with your choice of wood stains.

4. Build a hearth by mounting the hearth stone purchased from the masonry shop in front of the existing fireplace. Spread a thin layer of mortar at the foot of the fireplace and then lay the hearthstone in place. Make sure the hearth is level by placing the level on top of the stone and adjusting the mortar accordingly.

Tips & Warnings

• Start placing stones at the bottom of the plywood frame first and allow gravity to help "seat" the stones into one another.
• Make sure the existing fireplace structure can withstand the additional weight of adding stone to the front of it. If you notice cracking or a chipped fireplace structure, you may need to have a contractor replace the entire structure.

Resources

• Guide to mounting a fireplace surround out of wood or stone