Create a Magical Barrel Stave Wine Holder

This Magical Barrel Stave Wine Holder is a fun and fast little project you can make and is great to give out as gifts. It’s one of those things where you put in the wine bottle and it kind of floats magically, perfectly balanced. These are easy to make and while they serve no real purpose it’s one of those things that people enjoy – especially if it comes with a bottle of wine! And because it’s fairly small it is easy to store and bring out for parties.

Tools and Materials

There is not a lot to this project. You will need a barrel stave that is 2-1/2 inch or wider. My barrel staves come from Skull Creek Designs in Midland Michigan. As far as tools, a saw, a drill, and a 1-1/2” Forstner Bit are all that is really needed. Links in the bottom for the tools and materials I use.

By the way check out my blog and video on my Whiskey and Cigar Butler where I show you how to clean up the char on the inside of the barrel stave to keep your shop and hands clean while working with it.

Layout

With a tape measure mark off and 8-1/4” length. Next, on the side mark a 45 degree angle for the foot. At the other end, measure down 1-3/8” and mark the center. Use and awl to punch a hole for your drill point later.

Cutting

The first thing to do is cut the stave to length. I used my table saw bu ta compound miter saw works really well for this operation. Set your saw to 45 degrees and secure your work. The barrel stave curves in two directions and you don’t want the saw to bind while you are cutting. This 45 will be the bottom of the wine holder.

Drilling

Next, you need to drill the hole for the bottle neck. I recommend a 1-1/2” hole but you could tighten it up and use a 1-3/8” hole if your barrel stave is a bit undersized. Mount your forstner bit and center it over the hole you made with the awl. Drill through the barrel stave but be careful as the large bit can grab and twist the drill out of your hand.

Sanding

Next, take 60 grit sandpaper and give the top and sides a light sanding just to knock off the dirt. And then go to 220 grit and sand everything lightly. Be sure to round over all of the edges. Sand lightly, you do not want to knock off the patina. And then wipe everything down to remove the dust

Routing

The last machining step is to round over the edges of the hole. I used a 1/8” roundover bit but you could go as large as 3/8” depending on the look you want. Hit the routed edge with 220 grit sandpaper to remove any roughness.

Finishing

Now we can move on to finishing. First, we will hit it with a stain to even out the freshly sanded areas and the aged barrel patina. I chose a Minwax Dark Walnut. I like it because it bring the piece to a darker look so it gives it a more even color and an older antique look. Wipe it on then rub off the excess. I usually allow 24 hours for it to fully dry.

Once it is dry, I wipe on 3 coats of Minwax Polyurethane, sanding with 320 grit sandpaper between each coat. Then I apply a final coat of past wax.

All of that makes it silky smooth.

Rounding the edges of the hole with a router

Congratulations

Hopefully you had a chance to think about this project and do it. It is really fast and easy and you can impress your friends with your awesome woodworking skills.