How Do We Make Fireplace Mantels?

We get a lot of questions about the mantel manufacturing process and are always excited to share it! Here's a fun video that showcases the main steps in a visual way, but we're also outlining the process below for those of you interested. As always, thanks for following along! 

Mantel Making Process

STEP 1 - SALVAGE: We purchase the majority of our lumber for our mantels from agricultural buildings and barns that have been torn down in the upper Midwest. Here's a cool photo of one of the buildings we purchased material from for a batch of mantels and beams. We are proud to be able to give this wood a second life in the form of reclaimed beams and mantels. 

STEP 3 - UNLOAD: Once the beams / lumber is delivered to our yard, we unload them and get them stacked up and ready to head to the kiln.

STEP 4 - KILN DRY: The first major step in the manufacturing process is kiln-drying. This allows us to make sure that any bugs, fungus, etc. are killed and any moisture is removed before we start to process the material.

STEP 5 - DE-NAIL: A very important step in the process is our de-nailing process which involves removing (by hand) any debris including nails, metal, etc. that might be present in the wood.

STEP 6 - MILL: After the material has been de-nailed, they head to the mill for rough-cut and "square up" so that the side that will eventually face the wall / fireplace surround is flat.

STEP 7 - HAND SAND: We then hand-sand and clean up each beam (type of sanding varies depending on mantel style)

STEP 8 - BORE: We bore all of our mantels with holes that accept our floating bracket system. 

STEP 9 - FINISH: Depending on the mantel style, we may finish with a stain or clear-coat.

STEP 10 - PHOTOGRAPH / MEASURE / SKU: Each mantel is photographed individually from multiple angles so that customers know what they are purchasing. All of our mantels are one-of-a-kind and listed separately online. We also measure and assign a SKU to mantels during this stage.

STEP 12 - PACK AND SHIP:  When a mantel sells, we then pack and ship with love and send off to our customers around the USA. (Free shipping to the lower 48!)