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Step 2The First Cuts Are the Deepest...
The entire success of this project hangs on getting your cuts right, so take your time and do the old "measure twice, cut once", thing.
We are going to start by cutting the barrel in half, this is simple enough to mark. Measure the barrel, divide by 2 then make a line all the way around at the height. Apply jigsaw liberally.
Now that you have "cleaved yon barrel in twain", it is time to work on the "top" of the barrel, this is the one with the drain holes and plugs in it. Those plugs are actually called "bungs" and the holes, well you get the picture, and you have learned something about the etymology of your bunghole. Next, we are going to cut a goodly sized chunk out of the side of the barrel making the front of the chair. Mark a centerline and then measure 14" each direction from it along the outside of the barrel and mark those lines and cut all the way down to the natural rim around the bottom of the barrel. This 28" section will be removed with the next cut.
This is probably the most important cut you will make. In order for this piece, which we will be using later, to maintain it's shape and rigidity, you will need to make an angle cut to keep a portion of the lower ring of the barrel with the slab. After removal set this piece to the side for use later.
Go back to the shell of the chair which now clearly has a front and a back. Mark the centerline of the back and then measure and mark 8" on either side of center, let's call this mark "A". Next measure 7" down from the base to "A", mark it and make that straight cut.
Spin the shell back around and make two marks 2" deep from the front edge, one just above the base ring and another 9" up from the base. Cut these lines and now you are ready for the fun part, grab your safety gear it is time to bring the fire...
We are going to start by cutting the barrel in half, this is simple enough to mark. Measure the barrel, divide by 2 then make a line all the way around at the height. Apply jigsaw liberally.
Now that you have "cleaved yon barrel in twain", it is time to work on the "top" of the barrel, this is the one with the drain holes and plugs in it. Those plugs are actually called "bungs" and the holes, well you get the picture, and you have learned something about the etymology of your bunghole. Next, we are going to cut a goodly sized chunk out of the side of the barrel making the front of the chair. Mark a centerline and then measure 14" each direction from it along the outside of the barrel and mark those lines and cut all the way down to the natural rim around the bottom of the barrel. This 28" section will be removed with the next cut.
This is probably the most important cut you will make. In order for this piece, which we will be using later, to maintain it's shape and rigidity, you will need to make an angle cut to keep a portion of the lower ring of the barrel with the slab. After removal set this piece to the side for use later.
Go back to the shell of the chair which now clearly has a front and a back. Mark the centerline of the back and then measure and mark 8" on either side of center, let's call this mark "A". Next measure 7" down from the base to "A", mark it and make that straight cut.
Spin the shell back around and make two marks 2" deep from the front edge, one just above the base ring and another 9" up from the base. Cut these lines and now you are ready for the fun part, grab your safety gear it is time to bring the fire...
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Sep 26, 2009. 9:56 PMnatcrazz
says:
I'm not sure how to make the angled cut from this step. In the picture, is it from point A to D?
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2
Sep 28, 2009. 10:49 AM
Monkeybrad (author)
says:
Monkeybrad (author)
says:
I am not quite understanding the question. If, in your diagram, C is the bottom of the barrel, then the cut is from A to D, but A would need to move down. The idea is to create an inside bevel for the spring loaded seat to match up with in the final product. I hope that helps.
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1
Oct 2, 2010. 5:04 PMstevenh429
says:
I have been seeing this Instructable for about forever now, so I decided to rate this 5/5 :)
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Sep 28, 2009. 6:15 PMnatcrazz
says:
It did help. My chair is completed and it's great. Thanks a lot.
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Sep 26, 2009. 10:02 PMnatcrazz
says:
Sorry, I've been having trouble with the image.
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Sep 26, 2009. 9:58 PMnatcrazz
says:
Here's the Image.
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May 29, 2009. 10:41 AMAfro Tim
says:
I always wondered where the word "bunghole" came from. Thanks for that fun fact! Yep, it was definitely worth coming in to work today to learn that.
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