How to Face a Fireplace With Sheetrock
- 1). Place a ¼-inch bit on your drill. Drill 3-inch-deep holes all over the surface of the fireplace, along mortar lines if you have them. Work vertically and then horizontally so that you have an even grid of holes across the entire face.
- 2). Hammer a ¼-inch cedar plug into each drilled hole. The tops of the plugs must be level with the existing surface of the fireplace surround. Attach spruce straps horizontally over the whole fireplace surround, using 2-inch drywall screws and sinking them into the wooden plugs.
- 3). Follow the mortar lines with the edges of the straps, if applicable. The new wooden facing of the surround must be smooth and level all over. Cut 5/8-inch sheetrock to size with a drywall saw and attach it over the spruce strapping with drywall screws.
- 4). Cover the entire surround with sheetrock. Keep the vertical and horizontal seams aligned everywhere. Apply joint compound thinly along each seam with a putty knife and cover each seam with appropriate lengths of joint tape. Allow the seams to dry overnight.
- 5). Apply mud to the entire surround smoothly and evenly with the putty knife; be generous with the drywall mud so that all of the seam work and screw holes are covered. Sand any rough or uneven areas lightly with fine-grit sandpaper and paint or finish the surround as you wish.
Source...