FROM BARREL TO
FINISHED PRODUCT
Barrel staves Barrel top Barrel top Barrel tops
A B
C D
Barrel top clamped for gluing Table centre being constructed Table centre showing crucifix top support oak peg joint detail
Stave pegging detail and below.....

..... the finished table
E
G
MAKING A PATIO TABLE

A - The staves, sorted into size and wire brushed ready for production.

B - The inside face of a top before cleaning and sanding.

C - The outside face of the same barrel top.

D - First stage, rough cleaned tops.
Finished patio table
F
E - Tops generally require gluing to strengthen them.

F - The centre 'tower' of the table takes shape - note the cruciform jig clamped to the top to retain the shape whilst glue and dowels set.

G - 'Curciform' of 2 staves make up the support for the table top
All products start with the old barrel - the next step is to remove the metal bands that retain the barrel shape, once done the barrel collapses to leave the staves and the two ends.
Now begins the cleaning and sanding of both the staves and the tops. If used for outdoor products I tend the leave the barrel pieces just roughly cleaned by wire brushing and sanding. For indoor use more of the wood is removed to leave a lighter oak finish.

As barrels have been used to store wine and whisky for many years the wood colour is much darker than natural oak and therefore the product colour is fairly dark too. The inside of the staves, which were initially 'fired' during the coopering, are almost the colour of plain chocolate.

The top of the Patio Table shown is made from oak reclaimed by 'planking' old railway sleepers. All joints are strengthened with beech dowel pegs.

..... more

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