Step 1: Gather Materials and Get Stoked!
You don't need much for this project which is great!
BUT, I totally understand that wine barrel wood is not exactly "easy" to come by. However, if you can find it at a local winery, online, or just happen to know "a guy", get some and make something awesome!
- 8 x Oak Wine Barrel Staves (Similar in size if possible)
- ~25-30 1 5/8' Wood Screws
- RYOBI 10 in. Sliding Compound Miter Saw: http://amzn.to/2q1klHw
- RYOBI Miter Saw Stand: http://amzn.to/2p1072e
- RYOBI Power Drill: http://amzn.to/2q1l5wn
- RYOBI Impact Driver: http://amzn.to/2q1l5wn (not necessary but good to have)
- RYOBI Circular Saw: http://amzn.to/2q1l5wn
- RYOBI Drill Bit Set: http://amzn.to/2oKKWXi
- Tape Measure: http://amzn.to/2qMtJ1c
- 12” Rafter Square: http://amzn.to/2phZUIt
- Hand Sanding Sponges: http://amzn.to/2oHa6pP
VIDEO / AUDIO EQUiPMENT
Step 2: Size Up Your Staves
Above is a picture of the 8 x Oak Wine Barrel Staves I have.
They have a ton of character and are so awesome and I was so stoked to make something with them. The thing to note is that, if possible, you should get staves that are of similar width and thickness to make the project easier.
Also, wine barrel wood is both curved and uneven in terms of thickness, so remember that going in as your pieces will not all line up perfectly (that is part of the charm of course!)
Step 3: Make All Your Cuts
I had seen a cool / simple design for a barrel stool and I did some math in my head and figured out that I had enough material to make it (this was just based on a picture - no designs or measurements, so I just went with what I thought would work and made my stool the size that made sense with the material I had).
Picture 1 shows the various cuts that I made, with Pics 2-5 showing me being super cool and actually making them. Again. with the wood being oddly shaped, you won't get 100% perfect cuts. However, as a DIYer, you should both do your best but know that you're going to have to give a little to make it work. I don't know what I'm saying so I'll stop now...
Here are my cuts with rough measurements which I cut on the spot based on my own mental design:
- 4 x Legs (about 17" each) made from 2 x Staves
- 2 x Upper Supports (about 8-9") made from half of 1 x Stave
- 4 x Lower Supports (about 14") made from 2 x Staves
- 7 x Seat Staves (about 14") made from 3.5 x Staves
Step 4: Assembly Part 1: Legs
Note - for everything you'll see in the assembly process, I pre drilled all of my holes before screwing in screws to avoid the wood splitting. It's old - didn't want to risk it.
I started by making my to legs pieces using one upper support and two legs for each piece. The first picture shows the final design, with the next two showing me "in action"!
Step 5: Assembly: Part 2
I took my four lower supports and assembled them. Two pieces were turned out, two were turned in - this was to make the bottom supports fit around the legs - see the next step for clarity. More sweet action shots of me assembling!
Step 6: Assembly: Part 3
I then combined Assembly Steps 1 and 2 as such in photo 1. You can see that the legs pieces were wedged in between the bottom supports with the wider part of the leg faces facing the inward facing staves. This is how the design comes together to be very strong as well as sit even on the floor. I originally tried doing this all in a different order, but found this method to work the best to get an even seat.
Step 7: Assembly: Part 4
I attached my 7 x Seat Staves to the top of the legs using pre drilled holes and the asme wood screws.
I made sure to square up one side so that I could just square up the other with a circular saw once it was all attached. The staves are not going to be the same sizes, so just run with it - it will be unique - just like you!
Step 8: A Bit of Final Finishing
As stated before, I then used my circular saw to square up the other size and lightly sanded down my edges with some 120 grit paper.
At this point, the stool was done. There are a few things I could do to it additionally, such as put a sealant on it or really round over the edges. I might do that at some point, but for now, the stool looks great, is very sturdy, and I'm proud of my afternoon project!
Step 9: Admire Your Final Work!
Final stool was done! Simple, elegant, and very neat to see the dark purples from so much wine aging pop against the other grains of the old oak wood.
If you want to know any materials, tools, or have any general questions answered, make sure you check out Step 1 or contact me via my website, thecuttingbored.com and I would be happy to do answer them.
As always, thank you for reading! I would be so grateful if you could please subscribe to my Youtube Channel for future projects.
I put out videos every few weeks.