Step 3 - Make a template and Measuring
The best way to determine
the overall size that you want to make your doors to is to measure the
narrowest dimensions between the stones and then cut a piece of
cardboard in a rectangle slightly smaller than those dimensions.
Don't try to cut the
cardboard the shape of the stones. What we need to know is the actual
"rectangular" dimension that the door frame needs to be made
to.
This cardboard should fit
loosely leaving about 1/4" to 1/2" between the narrowest
points. Notice above that we ignored the 2 unusual stones when we made
the template because we will be chiseling these stones down a bit.
We do not need you to send
us the template if it is a rectangular fireplace opening. We just
suggest that you go through this exercise in order to determine the
overall finished size that you need the frame made to...
For arched openings, we
will need the template and your template should reflect the overall
outside size and shape that you want the frame made to. This is
important, because these doors must be custom made and we can't take
them back if they don't fit based on your measurements.
Custom doors like these
take up to 10 weeks to order...so the next step is to sit back and
wait a couple months or so.
Step 4 - Chisel large protruding stones
The picture above shows
the opening after the 2 larger stones have been chiseled away. Most
applications don't need chiseling, but these ones obviously were in
the way and had to go. It's best to wait for your doors to arrive
before you do any chiseling since you can use the frame to test and
see what really needs to be done...although your cardboard template
can suffice as well.
Step 5 - Installing door frame
Center the door frame as
good as possible. Install it using the hardware that comes with it.
Make sure that the frame is plumb and square. The best way to do this
is with a level on the face of the frame.
It is also very important
to test the action of the doors themselves as they may need
adjustments that cannot be done once you have mortared in the frame.
Notice that the gaps
between the frame and the rocks appear to be large and at first will
not look good to the eye. Don't worry, once you fill in the gaps with
mortar, it will look just like the stone was built around your frame.
Notice the size of the
mortar joints between the stones on the fireplace itself and you will
see that the gaps between the door and the rock are not much wider,
and in most cases are just like the rest of the fireplace.
Step 6 - Mortaring in the frame
Your almost done...now,
simply mask everything off and then mix up some mortar and hand pack
it into the empty spaces. You may need to reinforce the mortar with a
wire mesh backing in cases where gaps are really large. A quick
setting mortar with a little sand in it is excellent for this
application.
Matching the mortar of
your existing fireplace is usually pretty easy to do since most mortar
is gray in color. However, if your fireplace has a lot of soot around
the opening, you will either want to clean what's there or simply
smudge soot on your new mortar joints after it's dry.
The picture above is
computer generated and we made the mortar joint a different color and
texture so that you could see it better.
Step 7 - Send us a picture of your installation
Once you are finished,
send us a picture of your installation so that we can post it on our
website as an example. The example that we presented here was all done
by computer imaging...we would like to have real before and after
photos from our customers...
Sit back and enjoy your
new fireplace doors!
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