Its time for a new home project. This week on my old house its a fireplace fix up. Our 80 year old fireplace has had little upkeep in its life. Lucky for us back in the day things were built to last. I had suspicion that some of the brick mortar in the fire box was loose. Not wanting to burn down the house the only option was to get to cleaning.

The Fireplace Starting Point
Reading online there are many methods of cleaning off years of soot. Armed with a bucket, scrub brush, and a box of Trisodium Phosphate I got to scrubbing. Hours later and I ended up with this and some mild back pain.

Clean Fireplace
Once clean I could get a sense of the repairs needed. The mortar was in worse shape than I had thought. There were several gaps where mortar was entirely gone.

Missing Mortar
To the hardware store I go. New mortar, trowel, and mason sponge. Observe my professional repair. If moving electrons ever fails me for a job I guess I could fall back on masonry.

Fixed Mortar
The snowball has now started down the mountain. Although the fireplace is clean and once again safe to use it’s not as pretty as it could be. When we bought this house I foolishly promised my wife I’d fix it up how she wanted it. Reminding me of that promise she pointed out her dislike of the tile in front of the fireplace.

Original Fireplace Tile
Building up some momentum we ventured back to the hardware store to go tile shopping. We found some slate tile that we both liked. Those along with grout, tile adhesive etc I thought I was prepared. I was wrong but hey what else is new. For an area so small I assumed I could remove the tile with hammer and mason chisel. I was right. Behold, old tile gone. This was surprisingly easy.

Old Tile Gone
Not knowing anything about tile I assumed that I could skim coat over the existing concrete base and then lay tile on top of that. I don’t have any pictures of this because it was a large failure. There was no way I could level out the surface. I needed to put down a piece of cement board to get things level.
Back to the hardware store. I got the cement board brought it home, cut it to size and laid it in the opening. It looked great. Only problem is that it was too tall. To my dismay I would need to remove all of the old concrete in order to set the tile at the proper level. Again lacking any sort of power tool that could do this job I resorted to the universal fix it tool. A 4lb hand held sledge. Along with the my trusty chisel I began removing concrete. Lucky for me I was able to get under a slab and break it up into pieces. Many hours later I created this pile of rubble.

Fireplace Rubble
Its hard to see but its probably 4 buckets of concrete and tile. So now I had created a new problem. With the old concrete gone it was too low for the tile. Back to the hardware store, and a bag of concrete later I poured a new base for the backer board. I’m good at a few things. Turns out concrete isn’t one of them. It was uneven an had a few high spots. Worse was it was too high again for the tile. I may have verbalized my frustration with a strong four letter vocabulary.
Taking some measurements I found that I could still salvage the situation without another major demo job. My half inch backer could be replaced with a quarter inch backer. If I could remove the high spots I could make it work. Without hesitation I returned to my friend, Sir pounds a lot. My hammer and chisel returned to save the day. Chipping out high sections I leveled out the base. Here is what the board looked like.

Backer Board
Finally with the backer board down I was ready to lay tile. As the experts recommend I laid out the tile in the opening before cutting or glueing. I was replacing 4″ tile with 1/4″ grout. I bought 4″ tile and 1/4″ spacers. you would think things would line up. I was about due for something to go right. This was not it. Putting the tile in the opening I was an inch and a half short. Not sure why. I checked the measures and the spacing. Looked at the old tile and couldn’t figure out where I had measured or added incorrectly.
Turns out I was right all along. It was new tile that lied. The box said it was 4″ and the tile out of the box I measured was 4 inches as well. I got a bad feeling this tile was in expensive for a reason. Measuring a dozen more tiles not one was the same size. 3 and 3/4… 3 and 7/8… and even a few that were 4″. We promptly returned the tiles to Lowes as I refused to use them.
We venture out to a dedicated tile and stone store. We found a few square tiles that were much like the original slate that we had picked out. However we both spotted some hexagonal travertine tile that were a nice dark color. Perfect for hiding ash from the fireplace. Doing some quick calculations I was confident we could make it fit.
We purchased the tile and got home. It now dawned on me that instead of cutting maybe 13 square tiles I’m now going to have to cut about 50 two inch hex tiles to make a strait edge. Not only that but this edge was going to show. Which means they needed to have the edge rounded and cut side polished. Also there are now two cuts that can’t be done with a score cutter.
Back to the hardware store. New tools include a wet saw and various wet dry and papers. I set up in the back yard cutting tile after tile. When done I sat on the back steps with a bucket of water and sand paper polishing tiles. This was basically all day. I never polished rocks as a kid and now I know why. It is beyond tedious.
Laying out all the tile there was one tiny corner piece missing. Ever time I tried to cut it on the saw it would chip and break. I resorted to my other favorite tool, the Dremel. Add one cutting wheel, a pair of gloves, and safety glasses and you’ve got a custom cut tile.
All of the tile cut and ready next step, actually put it down. A quick instructional video on the internet and I was ready to go. The tile went down with little fuss. A day later I could seal the stone as it is a porous variety. Waiting another day for the sealer to set I could proceed with grout.
Mixing up the compounds I was ready to go. The grout went in without issue. Except for the fact I was about one scoop shy of having enough. Back to the hardware store for another bucket of which I used one trowel full. What a waste. After a few wipe downs we have new tile.

New Tile
Another day of cure time and we could return the other accessories for the final product.

Done Fireplace
It only took 8 weeks or so. What ever. It’s done. I declare victory.