This project makes for a beautiful frame but keep in mind that this is not a job or project for the inexperienced, the weak hearted, and minors. Working with glass and mirrors can easily lead to accidents.
1. Measure or determine the size of the mirror you want to enclose in the wooden pallet frame. Planks of wooden pallet often have the dimension of 3” x 48”.
2. Sketch the design of the mirror frame.
3. Determine the material used on the wall where you will attach the mirror on.
If the wall is made of timber or thick planks, you’ll need nails to attach the mirror.
If the wall is made of concrete, you’ll need concrete screw anchors. If the wall is made of concrete, you’ll need drywall screws.
If the wall is warped, you’ll need to use spacers to keep the mirror leveled and flat.
4. Procure the pallet.
For this project, you need to carefully select an undamaged wooden pallet.
Mirrors are heavy, any rotting or water damaged part of a plank supporting them will give and cause an accident.
5. Disassemble the mirror if it comes with its own frame.
6. Score the mirror to the size you want.
Note that scoring a mirror is simple but daunting. Get the best mirror scoring tool you can afford or have. Be careful. Wear safety glasses, gloves, shoes, and overalls. Don’t rush.
If the mirror you’ll cut is small (smaller than 2’ x 2’), a steel wheel cutter is enough to get the job done.
• Prepare the mirror for scoring. Use glass cleaner to remove stubborn dirt and stains. Then use alcohol to remove the remaining dirt. Use a microfiber cloth to dry the mirror.
• Secure the mirror on your work table if it’s too big. Place pieces of rubbers on the clamps to avoid damaging the mirror.
• Use a straight edge to guide you when scoring. You must start and end on the mirror’s edges. You must do this in one go.
• Break the mirror using your hands if it’s small or with the help of pliers if it’s big.
7. Get four planks from your pallet and sand them down. Saw them according to size.
If your mirror measures 12” x 12” and the width and thickness of your planks is 2” and 1” respectively, saw four 16” x 2” x 1” planks.
Basically, you need to add two times of the width of your planks to its length to get the perfect fit.
8. Miter the corners of the planks by 45 degrees. Use a table saw to make grooves that are thick as your mirror using a table saw.
9. Assemble the frame and see if the planks fit.
10. Insert the mirror inside the grooves.
11. Glue the planks together and clamp them until the glue is cured. You can use pocket screws to provide additional strength to the frame.
12. Apply the finish that you want. Just be sure to cover the mirror with painter’s or masking tape.
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