A client has asked me to build a frame for wall-mounting a 37″x 63″ x 1/4″ mirror. She’d like to frame the border of the mirror with decorative molding (which she plans to paint).
I don’t have a workshop (I usually work on-site) and I have an arsenal of hand tools (circular saw, router, plate joiner, clamps, etc.) and a chopsaw. And I do enjoy a challenge.
Since she plans to paint it, I was thinking about using 1/2″ (1/4″?) plywood for the back and maybe 1×2 for the framing.
I would be grateful for any suggestions or recommendations about: a source for designs/plans (closed back vs. open, french cleat vs. hanging clips), tips on finishing the sides (edge-banding vs. tacking on wood strips), type of wood, anchoring the mirror in the frame, or anything else you might think is useful.
Thank you.
Neal
Replies
Made a couple of these, not that big, but close. First off, use the cleat because that much mirror is too heavy for clips.
Get the moulding she wants and make a mitered frame with the outside dimensions 1-1/2"+ 1/16" larger than the mirror. The extra 1/16" is so the mirror can sit in the frame easily. Use a band clamp and butt glue the moulding frame. If it's thick enough, put some small biscuits in the joints. Rabbet the frame to accept 3/4" finished stock. Get some straight 4/4 poplar and rip it to a width that'll be good for the mirror, 3/4" cleat, and 1/2" ply back. Build the frame to match the rabbet. Check the fit of the mirror to the frame. Cut a piece of 1/2" ply to a snug fit in the frame. Screw your cleat, and some corner blocks with screw holes onto the 1/2". Prime and paint. Drop the mirror into the frame followed by some thin cardboard or brown construction paper. Drop the back in and screw the blocks to the sides and bottom. Cut a cleat to match the wall. If the wall is crooked or the mirror doesn't hang straight, use two cleats to keep it close to the wall.
I did a few mirrors that size a couple years back and used a no-back approach. I screwed the bottom of the frame to the wall (countersunk screws) mounted the glass in the groove of the wood, then screwed the other 3 sides around the glass. Then I plugged the screwholes with 3/8" plugs, sanded and finished. I made the molding 1st with a 1/4" deep groove for the mirror and cut it with the miter saw on site.
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