Ken: Try the ' stepped ' drill bits - I have used them very successfully for drilling plexi in the past. You know, the ones that are several different sizes in one - they are a bit pricey, but they work. Dave Beauchesne
Last night I tried to install the new, revised 14 year old mantle piece that I fabricated out of an old sugar maple off-cuts and a 2" X 8" sugar maple slab. My mechanical engineering consultant convinced me to attempt to mount this mantle with out cutting into the stud walls and without using 45 degree gussets on either end. It did not work so today I am cutting the 45 degree braces for either end and bracing the mantle. The best plans of mice and men etc. The mantle slab is beautiful with a eurathane finish and golden oak oil based stain. I killed most of the worms in the slab and filled all voids with plastic wood. Then I wore out three belts on my belt sander before sanding it down to 220 grit. I just hope the client does not mess with it before I can get the braces installed. I have it temporarily braced.
At his point I am thinking that only exterior braces on either side of the mantle piece will work. If I can get the structural bracing OK, I won't have to worry that the owner will pile up stuff on the mantle and cause a house fire etc. I need some suggestions about how to make the 45 degree gussets look compatible with the rough cut and very heavy sugar maple slab set on the stone facing. I have been considering the concept of using some cast iron braces on either side of the fireplace surround but haven't found any 45 degree shelf type braces that look "colonial" enough to make it work. Would enybody have any sources that I might contact to get some OTR sources? Thanks for your help.
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