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The Making of a Barrel Stave Bar Stool

It all starts with aged dried white oak rough cut boards, freshly planed to 3/4" and jointed. Ready to start making the seat of the stool.


The oak is cut into strips 14" long and ready for biscuits.


The biscuits are in and the assembly is glued and clamped.


The process is repeated and the two 14" squares are glued and clamped together.


The stool seat blank is placed on a circle jig and a 13" circle is cut.


The seat underside is sanded to get ready for routing the recessed for the stool legs.


The underside of the seat is routed using a template.


A router roundover bit is used on the seat underside edge.


Four staves of approximate widths are chosen for the stool legs.


The stool legs are cut down to 29 inches.


The legs are machine sanded front and back, then hand sanded.


Staves are cut and sanded for the lower stool support


A half inch hole is drilled and an oak dowel is inserted.


The legs and lower support is stained prior to assembly.


A leg support is made from strips of oak that are notched.


The legs and supports are attached to the seat. Next comes the ring foot rest.


A barrel ring is cut and sanded.


A 14” wood template is used to make a perfect sized circle from the ring.


Holes are drilled and the ring is riveted together.


Stool put together, stained, and a hand rubbed Earth friendly tung oil is applied.





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