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To reduce the risk of injury user must read instruction manuals for all tools used in this project. Wear eye and respiratory protection. Use clamps to support work piece whenever practical.
If you are adding a frame to a mirror you already own, your dimensions may be different. The cutlist and steps are dimensions for a frame to fit around a 15" by 21" mirror. To begin, crosscut your pine plank at 52" creating two pieces. The remaining should be 20". This cut is quick and easy with the Dremel Saw-Max equipped with an SM500 Wood and Plastic Wheel. With your plank clamped, cut along the marked line, following it at the notch at the front end of your tool. Be sure to sit the foot of the tool flush against the board for a quick, smooth cut.
Next, use your Saw-Max and SM500 wheel to complete a series of rip cuts: • Cut the 2.75" wide strips as shown in the cutlist: cut one strip from the 52"pine piece and two strips from the 20" plywood material • Cut a 1.5" wide strip from the 52" pine • Cut a 2" wide strip from the 52" pine
Again using the Saw-Max tool and SM 500 wheel, cut all of your strips to the proper length. If you're following our dimensions, the 20" length pieces are already the proper size.
Take all the 2.75" wide pieces (2- 26" and 2- 20") and using the Dremel Miter Guide, cut a 45 degree angle on both ends of all strips to create the miter frame. To complete these cuts, swap out cutting wheels on your Saw-Max tool. Replace the SM500 wheel with the SM600 Wood & Plastic Flush-Cutting Wheel. Tip: Place the angled edge of the guide next to your intended cut line. Now, slide the guide back just slightly, leaving 1/8" of space between your intended cut and the guide to account for the offset of the blade. Clamp the guide down on top of your material and make your cut.
Lay out the mitered pieces in position, apply glue to the angled surfaces and join together creating the frame. Clamp into place and secure corner with nails.
Using the two 1.5" x 26" strips, glue and nail to each side of the frame overlapping the front of the frame by 1/4" and the back by 1/2". Glue and nail 2" x 23" pieces to the top and bottom evenly spacing the overhang on each side. Make sure to keep the pieces flush with the side mounted pieces on the backside.
Next, we made cuts in our plywood material to use for the backside of the frame to create a space to secure our mirror. Remember, the width of the strips you cut can change depending on your mirror size. We put our SM500 wheel back on our Saw-Max tool and cut four 2.5" wide strips: • (2) at 20" wide for the top and bottom • (2) at 20 3/4" tall for the sides (to find the proper length for the side pieces, we measured the distance between the top and bottom strips)
Using wood glue, secure all back pieces of the frame. These will help secure the mirror into place.
Finally, place your mirror glass into the recess and fasten glass retaining clips to hold the mirror securely into place.
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