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| Preparing the Lumber for the Wine Barrel |
The first step in making the staves was to get the material straight and cut to length. This required 'straight line ripping' one edge. This was done with a jig (as shown below) that allows an electric 'hand' circular saw to run against a straight piece of steel, which creates a'well, 'straight line' along one edge. The board is then 'ripped' to width on a table saw.
Once we had the straight stock, we trimmed the ends to approximate length.
The next phase of the project was tricky. We needed to cut each barrel 'stave' to its proper length and we had to cut the curved shape on both sides, a slight bevel on both sides and a groove to receive a spline on both sides. Normal barrels don't have the spline and the construction method is much different. Because it is smaller the staves don't have to be as accurate. Ours need to be cut on a CNC machine (that's Computer Notated Cutting). In order for the machine to know what to cut, the information had to be digitally entered. We started with my CAD design, shown below,
and then Robert, the head engineer at Premier Eurocase programmed it into his machinery. We were then ready to deliver the 'stave blanks' to them and have them do their magic! Here is a stave being cut:
Now that we had the staves, we had to complete the final cut in our shop, because the geometry of the CNC would not allow it to make it. Here is the jig we designed to make the cut with a hand router.
The tapered cut we made will allow the stave to 'mate' with the barrel end. We were now ready to start installing staves on the barrel 'form'. Each stave will have to be bent to the form and then mated, via the spline to the stave on each side of it.
Now that we have all the staves cut, we will begin installing the staves on the barrel form in assemblies of 4 or 5 staves. These will be glued up and will be removable when we need to disassemble the barrel for shipment to Devil's Thumb Ranch. In order to do so, we made 'Stave Braces' which will be attached to the assemblies on the outside of the barrel, which will not show because it will be behind a stone wall.
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