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DIY Fireplace

Nameless Range

Well-known member
Joined
Jun 6, 2013
Messages
6,016
Location
Western Montana
With the building of our new home, one thing I really wanted to do was build a rock fireplace out of local rock. I had in been enough abandoned old cabins to assume that if some backwoods miner could do it 150 years ago without Youtube or Home Depot, that even I could do it. It was challenging and I learned a lot.


To begin with, I needed rock. To pick rock on National Forest, as long as it isn't valuable metals, requires a Free Use Permit, which is given at the District Ranger's discretion, and requires details about amount, purpose, location, etc.. That, or get permission from a landowner or the owner of a patented mining claim. I picked my rock from the hills west of Jefferson City, only a few miles from my home.

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Scree is hotter than you can imagine once the sun comes up. Most of my picking was done in the early morning hours, which were beautiful.
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It took about a dozen trips, the axles on my truck could only take so much at a time. Ford Ranger's aren't built for hauling rock. I was told to pick twice as much as I thought I would need, because putting the fireplace together was like piecing a puzzle, and some pieces you just don't need. This turned out to be true.
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It started with a gas fireplace from Smitty's in Helena, and a hearth framed out.

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At Mark's Lumber in Clancy, we picked out mantle. They had a great selection. We had it planed and cut to be 4 inches tall, 16 inches deep, and 6 feet wide. I sanded it and then coated it in polyurethane. I then plunged it to the fireplace frame with 4 8-inch lag bolts, as well as 3 L brackets on the top, which would eventually be covered in rock
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Next, I nailed up some roofing paper and lathe to the fireplace frame, which was 3/4 inch OSB tongue and groove. I used more nails than was recommended to be safe, so every 4 or 5 inches.

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After the whole thing was covered in Lathe, I put a 1/2 inch coat of Veneer stone mortar up on the fireplace and let it dry. This would serve as the base that I would mortar my rock to.
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I've heard that you should work from top to bottom, but I did it otherwise. This is where it started to be fun. I used heavy igneous rock, and often had to "strap" the rock to the mantle while the mortar dried.
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I did have a couple of instances where rock didn't stick. It seemed important to wet the rock prior to spreading mortar on it. It also was important to clean the rock as I went. I used a toothbrush, because if you let the mortar dry on the face of your rock, you'll never get it off.
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Eventually, I had all my rock up. Next came the grouting.

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I wish I had more pictures of the grouting process. I used the veneer stone mortar that I used to get the rock up there, but I dyed it black with carbon. It looks good but that stuff is terribly filthy, it sticks to skin, and doesn't wash out of clothes, once it dries all it has to do is get wet again and it becomes a mess. I used a grout bag, which works the same as a pastry squeezy-thing for frosting. Here is the finished product after grouting. The very bottom wasn't grouted because I did that after the flooring was put it.
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So the fireplace sat that way for a while. In the meantime the floors and trim in the house were finished. This weekend we finally got moved in. First item up - the Moose. I had rocked around the 6 inch long, half inch diameter bolt when I began putting rock up, and that's what he was hung on.
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This project was a lot of fun. I am pretty clueless when it comes to anything involving craftsmanship, and I pulled it off. The rock came from the Boulder Batholith, and was only moved a few miles from it's original resting place. It is covered in green,orange, and white mosses. Supposedly you can spritz water on them occasionally and they will maintain. Putting up the fireplace took a couple weeks, and I certainly didn't do it all myself. I had a lot of help from family.
Picking rock took about a dozen trips into the hills, which began over a year before I ever started slapping rock up. Those trips were the most fun, and it turned out to be great family time. I'll end with a picture of the best rock picking partner you could ever hope for.
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Looks great I have done two of those myself in each of the two houses I have just bought or built the last few years. However I was afraid to use real rock because of the heavy weight issue of building them. I used stack rock in my last one. A guy can't imagine how much work is involved in those things until you do one yourself. I love the black mortor it really set the rocks off very nicely done.
 
Nice work. It sticks in my head that my dad kept the lichen vital with a beer/water spritzer. (Might have been an excuse to keep a few in the frig?)
 
Wow looks great!

I lived in my house for 8 years with a unfinished fireplace because I didn't know anything about the process and was dreading it.

In then end I had a blast doing it and was very, very sorry I didn't do it earlier. I did have a setback when my hearth stones didn't stick once but like you figured out you have to get them soaked up first.

Not as big and fancy as yours but was entertaining. I liked doing the grouting the best.

If I was ever to build a house again I would definitely do a bigger fancier one.
 
Very well done! I'm afraid to show that to the missus as she's wanting rock around our existing gas fireplace. Not sure I want to be goat-roped into doing it myself, but I am cheap so probably will...
 
Nice job. I do a lot of simulated dry stack where the mortar is recessed back from the surface and not readily visible, but instead of a veneer, the stones are stacked atop each other and run to 5-6" deep. Lots more labor intensive and uses much more rock but has a nice effect. I usually wind up handling each rock at least a half dozen times.

I had a veneered flagstone fireplace in my house in Denver which was covered in moss and lichen and the best way to keep it alive is to spray it every 2-3 weeks with beer. Yep, beer; it moisturizes and feeds the lichens at the same time.
 
Wow, that looks absolutely fantastic! Nice work.
 
Thank you all for the positive feedback.

noharleyyet, It's funny you ask that. I didn't sooner buy the stuff at Lowes before I was bleeding all over the parking lot trying to load it in my truck. Even just cutting it was dangerous. I used leather gloves and tin snips, but having something like welding gloves to protect my forearms would've prevented a fair amount of blood loss and vulgar language.
 
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