When my step daughter wanted to upgrade the fireplace mantle in her family room, we worked from a picture in a magazine she had, to come up with a design that was similar but would work in her room. We also added some crown molding and then repainted the room.
Since all work was to be painted, we were able to fill screw holes and the saw kerfs we used to curve the crown molding. For filler we used Bondo, which while designed for the automotive industry, it is a great product for woodworkers to use. It’s easy to work with, tough, and permanent.
I’ll try to get some more pictures showing the finished mantle from a closer position. I keep forgetting to get them.




Making the mitered pilasters, using blue painters’ tape. This is an excellent way to make long miter joints easily. This is surprisingly effective, and very dependable in getting perfect results.
When laying out the flutes try to use odd numbers of flutes. The same holds true for many woodworking designs, including building entertainment centers, an odd number of components looks best, carving shells and much more. I used to know why that holds true, but at the moment, I can’t recall. I’ll probably wake up at two in the morning with the reason.
Dry fitting the upper mantle is a good idea as it allows you to make changes as you work. If you don’t like something about how it’s starting to look, you still have the opportunity to make changes without too much trouble.
Notice the saw kerfs on the crown molding. The molding was cut almost completely through to allow for bending. This was done with a chop saw and thin kerf blade. All of the kerfs were easy to hide with the bondo.
Hope you enjoyed this post.
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com




































24 comments so far
Dick, & Barb Cain
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7049 posts in 1199 days
posted 617 days ago
Boy!
What an astounding upgrade, you turned a plain looking room into what’s now fit for a palace.
Thanks for the reminder on using Bondo. I always makes me think auto body work.
Are you sure you have enough clamps? ;o)
-- -** You are never to old to set another goal or to dream a new dream ****************** Dick, & Barb Cain, Hibbing, MN. http://www.woodcarvingillustrated.com/gallery/member.php?uid=3627&protype=1
GaryK
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9551 posts in 888 days
posted 617 days ago
Great blog and end result, Lee!
Also a great idea about the bondo in the kerfs of the moulding!
-- Gary, East TX -- The longest journey begins with a single step.
TomFran
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2515 posts in 894 days
posted 617 days ago
That’s an amazing transformation, Lee. You are a MASTER craftsman! Thanks for the great tip on the “Bondo” too. I’ve used it on cars, and you’re right, it is easy to form and sand, and is very permanent.
-- Tom, Surfside Beach, SC - Romans 8:28
dennis mitchell
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3791 posts in 1214 days
posted 617 days ago
Good looking job!
-- http://www.woodsongsfurniture.com
Lee A. Jesberger
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3710 posts in 879 days
posted 617 days ago
Thank you guys.
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
mrtrim
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1698 posts in 780 days
posted 617 days ago
great looking job lee ! i havent kerf cut any crown in a few years , guess im gettin lazy i usually use the flex mold now . you did a really nice job of it .
Lee A. Jesberger
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3710 posts in 879 days
posted 616 days ago
Hi Verne;
Thank you sir!
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
Dadoo
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1723 posts in 890 days
posted 616 days ago
A couple of great tips here Lee! Bondo and placing an odd number of flutes. I also like how you hid the electrical (round covers) by going with one outlet. Another good idea.
-- Bob Vila would be so proud of you!
Lee A. Jesberger
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3710 posts in 879 days
posted 616 days ago
Thanks Dadoo;
Who’s Bob Vila?
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
Damian Penney
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1030 posts in 891 days
posted 616 days ago
Wow, very cool, filling kerf cuts with bondo to bend crown is a great idea, one that I’ll be filing away :) The upgrades to the room look stunning.
-- I am always doing that which I can not do, in order that I may learn how to do it. - Pablo Picasso
Lee A. Jesberger
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3710 posts in 879 days
posted 616 days ago
Thank you Damian.
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
Sparky977
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56 posts in 619 days
posted 616 days ago
What a transformation of that room! Very impressive.
I think the reason that an odd number is best is because its more pleasing to have something in the center. Our eyes and brains can pick that out. This is also a good guideline for balusters in a stair railing or balcony.
-- I get payed to play with power tools! What could be better than that?
Lee A. Jesberger
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3710 posts in 879 days
posted 616 days ago
Thank you sparky;
Both for the comment and explanation.
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
Karson
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25873 posts in 1300 days
posted 616 days ago
Ah Bondo to the rescue. I’ve filled many a chip and knot hole in something to be painted.
The room looks fantastic Lee. Great job.
-- What happens in the workshop stays in the workshop. No wait that doesn't sound right. Karson Southern Delaware karson_morrison@bigfoot.com †
Thos. Angle
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4013 posts in 862 days
posted 616 days ago
Great stuff Lee. I have used Bondo to repair saddle trees and fill knot holes and who knows what all else. Wouldn’t be without it. I think if I remember right, the odd number is to keep the eye from trying to divide the piece. I just know it holds true in a lot of areas.
-- Thos. Angle
Lee A. Jesberger
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3710 posts in 879 days
posted 616 days ago
Thank you Karson.
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
Lee A. Jesberger
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3710 posts in 879 days
posted 616 days ago
Hey Thomas;
Thank you for the kind words, and the input on the odd number rule.
The added bonus is I like the smell of it, and it dries fast.
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
dlcarver
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261 posts in 629 days
posted 616 days ago
I use bondo in most of my habitats for birds. I have even used it on decoys. Check out my pintail in my projects gallery. The whole rump area is holding the tail on this duck with bondo. The habitat in the Black-necked Stilt shore bird, is all done with bondo. I tell about it there. Good stuff to work with. Your work is fantastic.
HAVE A GREAT ONE…. HAPPY EASTER!!!
-- Dave Leitem,Butler,Pa.,http://dlcarver.etsy.com
bryano
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546 posts in 833 days
posted 616 days ago
Awesome Job Lee
-- bryano
Lee A. Jesberger
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3710 posts in 879 days
posted 616 days ago
Thank you my friends!
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
Bob #2
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3056 posts in 921 days
posted 615 days ago
Son of a gun bud you are the man!
Odd number to recover mesuring errors, kerfed moldings , bondo.
Where did you learn all that stuff and how the heck did you get such a good result?
I do the odd bit of this stuff but not to the extent you have taken it so I can really appreciate your skill.
Good on you Lee.
Bob
-- A mind, like a home, is furnished by its owner
Lee A. Jesberger
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3710 posts in 879 days
posted 615 days ago
Hi Bob;
Thank you.
For one, working with an incredible designer, who was very much into design and proportion, and authenticity. I renovated and worked on many historic buildings in Philadelphia, I got to see how it was done in the 18th century. Although bondo wasn’t approved by the Philadelphia Historic Commission, we could use a particular brand of two part epoxy for any repairing of rotted wood, (like window sills).
Moldings on arched doorways and windows were kerfed in the same manner, but with a much finer blade whick required little or no filler.
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
EdC
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458 posts in 740 days
posted 551 days ago
Wow your work always amazes me, you are true Artist Lee.
What a diference before and after.
-- Ed - Milan, IN
Lee A. Jesberger
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3710 posts in 879 days
posted 551 days ago
Hi Ed;
Thank you for the kind comments.
They’re always appreciated.
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com