Rustic Mirror Frame (metal)

[HainesNYT]

It’s that time of the year...last minute DIY projects!!! So, neighbor’s wife asked me to build a metal mirror frame like one she saw at a local restaurant....so that’s the idea here.

They are getting ready to remodel their bathroom. One of the current mirrors measures 36x42. I’m going to build the frame for that. It will have a 1” square tubing frame around the mirror, with a second frame, made of 1”x3” rectangle tubing. It will be connected with used horseshoes.

[HainesNYT]

Something like this

[HainesNYT]

Outer frame is cut and about to get welded.

[HainesNYT]

Here’s the math on it.

[HainesNYT]

48x54 OD
42x48 ID

[HainesNYT]

Inner frame is cut.
36x42 ID
38x44 OD

[HainesNYT]

I planned for a 2” gap between the two frames. I used pieces of scrap, totaling 2”, to ensure the smaller frame is centered in the larger frame. I also wanted the smaller frame to stand out from the wall a little, so there are 3/8” blocks under it.

I’m using used horseshoes for this build. Finding uniformed sets is a little difficult. [emoji2959]

[HainesNYT]

All 4 corners done like this.

[HainesNYT]

Sides are done. Still have to weld the top.

[HainesNYT]

All welded up.


I will do an accelerated rust treatment, peroxide and salt. One or two times maybe. Then I’ll probably clear-coat it.

[HainesNYT]

Pretty neat...never done the peroxide and salt before

[ktjones]

lookin' good!

[HainesNYT]

It’s finished. I should have took another pic or two of the rust treatment. I hosed it off / and whipped it down, and let it dry. Hit it with two coats of Rustoleum clear lacquer. I really like the way it came out.

I’ll get a picture of it when it’s mounted.

[lanceodom]

well done!

[HainesNYT]

I’ll get a better final pic when they finish remodeling the bathroom and they actually mount it. She loved it.