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Custom Slate Hearth Surround with Flagstone and Reclaimed Rustic Steel
Looking to bring rustic elegance into your home with natural stone? This custom slate hearth surround blends raw slate flagstone, weathered steel, and mountain-inspired design to create a warm, handcrafted focal point for a cozy living space. Built by Jesse Schacher, owner of Blue Slate, Inc., this hearth showcases creative craftsmanship and the art of repurposing natural materials. Whether you’re designing a mountain cabin retreat or looking to upgrade your fireplace with a natural stone hearth, this project offers timeless inspiration.
A One-of-a-Kind Stone Hearth Design
This project began as a vision for a rustic yet refined heating stove surround—something beautiful, natural, and built to last. Here’s how Jesse built this custom slate hearth surround step by step:
🔨 Project Overview
Location: Living Room Corner
Materials Used:
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1″ Slate flagstone
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Reclaimed rusted steel roofing (heavy gauge)
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Thinset Mortar
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2×4 lumber and plywood (for building forms)
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1½” thick slate ledgestone for the stone mantel
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¾” slate flagstone pieces for the upper wall design
🧱 Step-by-Step Construction of the Custom Slate Hearth Surround
1. Building the Hearth Base:
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Jesse constructed a corner hearth form using 2” x 4” lumber and plywood.
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He cut pieces of slate flagstone to fit the top and sides of the hearth shape.
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Instead of a sharp point, the front edge of the hearth was angled—parallel to the stove’s front for a clean and balanced look.
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The flagstone pieces were set into thinset mortar on the top and sides of the form to complete the base.
2. Creating the Steel Backdrop:
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For the walls behind the stove, Jesse repurposed thick, rusted steel roofing panels that had been removed from a commercial building.
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He cut two 42” high steel sheets (about 3’ wide each) and mounted them on a backing form to cover the walls on both sides of the corner.
3. Installing the Slate Mantel:
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A mantel shelf was created using 1½” thick slate ledgestone, cut to measure 6” deep by 56” long.
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The mantel extends across both steel wall panels, creating a strong horizontal line and shelf behind the stove.
4. Designing the Slate Wall Scene Above the Mantel:
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Jesse used ¾” thick slate flagstone pieces to build a natural stone scene above the mantel, applying them directly to the wall with thinset mortar.
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Each piece was carefully chosen and placed like a puzzle to form the look of a mountain silhouette.
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The “peak” of the scene is positioned just off-center, giving it an organic, mountain-range feel.
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The upper wall design reaches about six inches below the ceiling, drawing the eye upward and adding drama to the space.
🌲 A Hearth That Reflects the Landscape
The final result is more than just a functional corner hearth—it’s a work of art. This custom slate hearth surround combines the strength of natural stone with the character of weathered steel to create a rustic yet elegant statement piece. It’s perfect for mountain homes, cabins, or anyone looking to add a warm, earthy feature to their interior.
🔗 Related Inspiration:
Explore our Custom Slate Photo Gallery for more rustic home ideas.
Looking for DIY-friendly slate tools and materials? Visit our Amazon Slate & Stone Tools Picks.
