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Three Fireplace Restorations From "Restoration Realities" episode DRTR-209

(Continued from page 1)

	The upstairs fireplace, before the restoration.

Fireplace Project #1: Retiling a Hearth

For the first of the three fireplace projects, we take on an upstairs fireplace that needs the existing tile to be reset. This is the most ambitious of our three fireplace projects and will take about four hours to complete from start to finish.

Tool and materials:

mortar
un-sanded grout (color-matched for the existing grout)
1/4" notched spreading trowel
rubber or cardboard tile spacers
rubber grout float
cold chisel and hammer (for mortar removal)
tile cutter
tile nippers
paddle mixer and a 1/2" electric drill
4" grinder with a masonry grinding disc
plastic buckets
large cellulose sponges
large piece of cardboard for a template
drop cloths
protective gloves
eye protection

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Fireplace Project #1 Steps:

• We began by removing as much of the existing mortar from the tiles and hearth as possible. Sweep and vacuum all debris (figure A). Next, we made a template out of cardboard of the hearth, and laid out the tiles on the template to determine if we have enough tile and to refine the exact layout (figure B).

  Figure A

  Figure B

  
  

  Figure C

• We used a wet saw to cut the tiles to the necessary widths to make the tile border (figure C).

Most tile can be cut with a scoring cutter, similar to a glass cutter. The cutter puts a deep scratch on the surface of the tile and pressure is applied to the sides to snap it. Tiles with very deep textured surfaces may need to be cut using a wet saw.

Wet saws allow you to cut faster and with greater accuracy than tile cutters and the cut edge is much cleaner and smoother. Depending on the size, power and optional features, a tile saw can cost between $300 and $900.

Wet saws utilize a diamond-tipped circular saw blade that is cooled by a continuous stream of water. The typical wet saw has the motor and blade fixed in an overhead position--the opposite of a standard table saw--and has a sliding table that is moved in and out by hand to move the tile under the blade. Below the sliding table is a metal or plastic reservoir that holds the cooling water and a re-circulating pump to direct the water up to the blade. The water cools the blade and provides dust control.

To use a wet saw, the tile is placed on the table and held in place by hand or with a clamp-- since the blade is fixed in one position--to cut the tile at an angle you simply need to hold it on the table at an angle. Turn on the saw, and move the table forward so the tile moves under the rotating blade. Depending on the thickness and hardness of the tile, you may need to make repeated cuts, lowering the blade further into the tile with each pass.

Safety Alert:

Here are some important safety tips for working with wet saws:

• Always padlock the unit in the off position when not in use.
  
• Always wear safety glasses when working with a wet saw.
  
• Be sure to unplug the unit when making adjustments.
  
• A safety apron is also a very good idea.
  
• Since you're moving the tile into a moving blade, work slowly, methodically and always be aware of the line of the cut and exactly where your hands are in relation to that
• cutting line. For smaller pieces, always use a clamp to hold the tile so that your hands remain safely away from the blade.

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