This DIY Coved Mirror project takes reclaimed pine and mahogany, with histories as rich as the wood itself, and turns them into elegant coved mirrors. Each step of this DIY project not only recycles materials but also reinvents them, turning what was once considered waste into a centrepiece for any room. Whether inspired by a desire to create, a passion for sustainability, or the love of a challenge, these coved mirrors serve as a striking example of the power of transformation.
DIY Coved Mirrors Project
Materials Needed
- Reclaimed Pine 1x8s: The soul of the project, providing a rustic charm.
- 2×2 Mahogany Balusters: Offering a rich contrast and elegance.
- Thin Underlayment Plywood: Used for the mirror backer panel.
- Wood Biscuits: For joining pieces securely.
- Lacquer: To give the final piece a shiny finish.
- Mirrors: Repurposed, breathing new life into old pieces.
Tools Required
- Thickness Planer: For ensuring uniform thickness and smooth surfaces.
- Table Saw: Equipped with an auxiliary fence for cutting the coves.
- Biscuit Joiner: To create slots for the wood biscuits.
- CNC Machine: For precision cutting of the frames and mirror holes.
- Bandsaw: For cutting the circular backer panels.
- Orbital Sander: For fine-tuning the sanding process.
- Router with Keyhole Bit: For creating a method to hang the mirror.
Crafting the Coved Mirrors: A Step-by-Step Guide
Rough Materials & Sizing
- Begin with reclaimed pine 1x8s cut down into 1.5″ strips and mahogany balusters sawed down the middle.
- Employ the thickness planer to remove any surface imperfections and achieve uniform thickness across all pieces.
The First Glue-Up
- Prepare to create laminated panels by arranging four pine strips as the core and flanking them with the halved mahogany balusters on each side.
- Clamp and glue these sections together, leaving areas without glue for subsequent steps. Flatten underweight to ensure even bonding.
Flattening
- Once the glue has dried, use the thickness planer once again to flatten and smooth the glued panels for uniform thickness.
Cutting the Coves
- Adjust the table saw with an auxiliary fence at an angle to start cutting coves into the panel faces. This requires precision and patience, adjusting the fence and depth of cut gradually to achieve the desired cove shape.
- Slice two of the laminated sections in half post-cove cutting for side frames.
The Second Glue-Up
- Temporarily assemble the frame pieces to mark wood biscuit positions and alignment marks with a triangle.
- Use the biscuit joiner to cut slots, insert the biscuits, and apply glue for the final assembly. Clamp tightly.
Sizing the Frames & Cutting the Mirror Hole
- After gluing, trim the frames to size and scrape off excess dried glue.
- Utilize the CNC machine to precisely cut out the hole for the mirror, including a ledge for the mirror and backer panel to rest.
Fitting the Mirror & Backer Panel
- Use the freshly cut frame as a template on the underlayment plywood and cut out the backer panel on the bandsaw.
- Ensure the mirror fits snugly within its designated space before securing the backer panel.
Final Sanding, Branding, & Finishing
- Erase saw marks and smoothen the frames with hand sanding, followed by an orbital sander.
- Each frame gets branded then sealed with several coats of lacquer for a glossy finish.
Hanging Method
- Decide on the hanging mechanism and opt for cutting a keyhole slot in the back of each frame using a router and keyhole bit for a simple yet effective solution.
Final Thought
By following these steps, the transformation from old, discarded wood to chic, decorative mirrors unfolds. It’s a project that not only challenges your craftsmanship but also embodies the essence of repurposing with purpose. These mirrors not only reflect your image but also the creativity and effort put into making something truly beautiful from the overlooked.
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