A landscape design firm I work with on various projects came to me with a client who wanted a mantle for their new outdoor fireplace. We decided upon one of the 200-year-old red oak barn beams I have in stock. After doing some layout to preserve the original joinery that was still intact, the next step was cutting it to length. To maintain the proper look, I used a traditional handsaw in lieu of more modern power saws.

The freshly cut end was glaringly bright in contrast to the two centuries worth of patina on the rest of the piece, so I used a torch and a few other methods to antique it.

The freshly antiqued cut end of the beam. After the finish is applied, the end blends in seamlessly with the rest of the beam.

A wider shot of the trimmed beam before finishing.

The finished beam installed on the new outdoor fireplace. The two pockets on the front face are original mortises that include the original draw bore pegs that were used to hold the tenon of a mating piece snugly in place. A portion of one of those tenons is still visible within the left side mortise.

Looking down the left side of the mantle.

Looking down the right side of the mantle.

A wider shot of the outdoor fireplace and mantle. The fireplace, patio, retaining walls, and all stonework were built by Doyle & McDonnell, Inc of Berwyn, PA.