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Cutting a fireplace mantel is left to the imagination of the person who is creating it. Each and every fireplace would be different. You have to create a working plan before you start up the project.
Different tools and material are required for cutting and creating a fireplace mantel. Some of the tools that are required by you are: Pry bars, safety goggles, wide putty knife, table saw, nail gun (pneumatic), level, pencil, brad nailer (pneumatic), disposable gloves, stud finder, and a power miter box.
The materials that are needed for cutting a fireplace mantel are nails, wood glue, plinth blocks, brads, decorative molding, wood adhesive, construction adhesive, decorative trim, spackling compound (interior grade), paint, and primer.
The material and the tools required for creating and cutting a fireplace mantel might vary upon the design and the plan you have for the project.
The first step in cutting fireplace mantel is to remove the molding if any that exists already. You could use a pry bar with a putty knife to do this. Make sure that you are not damaging the wall in this process.
Get a pine lumber and cut out the lengths needed. Use a power miter box and a table saw. For crosscutting you could use the power miter box and the table saw can be used for ripping. Assemble the three pieces of the wood with glue. The three pieces are the ones that come on the sides and the top. Use a stud finder to mark the studs on the wall. Now attach the three pieces you have already created to the fireplace. Now use the nail gun to fix them to the studs you are have marked. Any part that goes with tile should be attached with the construction adhesive.
The decorative moldings are now cut to the dimensions needed and are attached to the underside of the mantel. You could glue or nail as needed. Use the plinth and the corner blocks to give a column look. You could use the nail gun to attach these plinth blocks and the corner blocks. For the face of the mantel you could use the decorative molding. It should be cut with the miter box. Use the pneumatic brad nail to fix the decorative molding as this will not split the molding.
The minor surface imperfections can be corrected with the spackle (interior grade) and using a putty knife. After completion of cutting fireplace mantel, use a primer to give a coat to the mantel. Finally give two coats of paint to complete the construction of the fireplace mantel.
 
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