Measure the width and depth of the place where your mantel shelf will sit.
Use a table saw or circular saw to cut two 1-inch-thick boards or one 2-inch-thick board to the needed length. For most standard size mantels, use 10- or 12-inch-wide boards. Use construction adhesive and nails to attach the boards together to make a single, thick shelf, if you're using two boards.
Measure the length and width of your shelf. Cut pieces of 1 5/8- to 2-inch-wide trim molding to length to fit the edges of your shelf. Glue and nail the pieces into place around the edge of the shelf.
Use adhesive or nails to attach the shelf to the wall, the existing fireplace surround and the top of the existing mantel. The fireplace surround and the existing mantel serve to support the shelf.
Measure the length and width of the area under your shelf. Cut pieces of crown molding to length to fit the area under your shelf. Glue and nail the pieces into place under the shelf ledge.
Apply wood filler in any nail holes, and let it dry per the manufacturer's instructions. Sand the surface of the shelf smooth with a fine-grained sandpaper once the filler has dried.
Prime and paint or stain the mantel shelf.