How to Replace Brick Panels in a Chimney

Slide-In Panels

• 1

  Remove the screen, logs, log stand and anything else in the firebox.

• 2

  Remove the damaged firebrick panel. To replace a broken rear panel, the side panels will often have to be removed before the back panel can be taken out. Remove screws that hold any brackets and the panel in place and carefully remove the panels.

• 3

  Measure the firebox walls to determine the dimensions for the replacement panels.

• 4

  Cut the replacement panels to fit using a circular saw with a masonry blade or a masonry saw.

• 5

  Install the replacement panels, beginning with the back panel. The back panel often slides into bracket tabs or a flange. Replace any retainer brackets and screws, tightening the screws to secure the panel. Follow back panel installation with the side panels. If the side panels have one edge with a curve, the curved edge should be toward the front.

• 6

  Replace the log stand, logs, the fire screen and anything else that was removed earlier.

Mortared Panels

• 7

  Remove the fire screen, log stand and anything else in or around the firebox that can be detached.

• 8

  Remove the damaged firebrick panel or panels. Pull off any loose pieces and use a stone or mason's chisel with a hammer to remove the remainder of the panel and any mortar left on the firebox wall.

• 9

  Clean and prepare the area for refractory mortar and panels. Use a cleaner, if necessary, to remove any soot and debris from the site. Prior to mortaring, use a wet sponge to moisten the panels and walls where they'll be in contact with mortar.

• 10

  Apply refractory mortar for the back panel. Trowel the mortar onto the wall only where the panel will be in contact with the wall. In some cases, mortar should only be placed at the top and bottom of the wall, leaving a hollow space behind the center of the panel.

• 11

  Press the back panel into position. Use a brace or placeholder, such as a board or small piece of heavy furniture, to hold the back panel in place until the mortar cures.

• 12

  Apply refractory mortar along the gap at the bottom front of the back panel. Use a trowel to pack the mortar in and smooth excess mortar off of the top. Remove any mortar from the face of the panel before it dries with a damp sponge.

• 13

  Install each side panel. Apply a thin layer of mortar to the entire backside of the side panel and press the panel into the firebox wall. The side panel may be taller than the opening at the front of the firebox, so it may be necessary to insert the side panel into the firebox at an angle before pressing it into the wall until it's flat. Consider using a rubber mallet to tap the side panel into place gently.

• 14

  Brace the side panels in the same manner as the back panel to keep them in place until the mortar adequately cures.

• 15

  Pack refractory mortar into the seams created along the bottoms and edges of the side panels.