Simple DIY Barrel Save Whiskey Coasters for Your Bar

I love these simple DIY barrel stave whiskey coasters. They are perfect for you home bar and go with almost any décor. AND they are a great conversation piece. These barrel stave whiskey coasters are fast and easy to make and something you will be proud of once complete. You can make these as gifts for friends too!! I’m making several for our upcoming Christmas party.

By the way if you don’t have time or tools to make these? Visit my Etsy Store at www.etsy.com/shop/30MinuteWoodshop

And follow this link to my Video to see how it is done. VIDEO LINK

Tools and Materials

If you made the Whiskey and Cigar Butler (link here) then you will have a few pieces of wide barrel stave left over and ready to cut. If not then visit Skull Creek Design’s Etsy Store and order the wide staves. Make a note that you need 4” wide staves minimum 4-1/2” are better and Travis will fix you up.

For tools you should have a saw and you will need a 90mm Forstner Bit.

Material Prep

If you bought new stave you will need to knock off the char. You can see how I do that early in this VIDEO. Seal in the remaining char and soot with a coat of polyurethane to help keep your shop and hands clean while you handle the material.

Next, you will need to sand the outside of the stave to remove most of the dirt. I started with 60 Grit and went to 100 then 220 grit. DO NOT OVER SAND. All you want to do is to clean off the worst of the dirt and grime. Leave the rust, barrel band marks, and paint. These give it character.

Wire Brushing the char off the barrel Stave

Layout, Cutting, and Marking

Measure the width of your stave and cut as many square pieces as possible. Next draw and “X” from corner to corner to mark the center. I used an awl to create a small hole for my drill bit.

By the way – don’t be a slave to the sketch. You can do this with and 3-1/4” Forstner bit or even an 3” Forstner bit and shrink the overall size. Just make sure your glasses will fit.

Drilling

With everything cut and the centers marked you are ready to out the depression. This is 90mm (3-1/2”) diameter and 3/16” deep. I suggest you use a drill press to as controlling a very large bit in a hand drill is difficult and can be dangerous.

Finishing

At this point I chose to apply a dark walnut stain to create the look of aged antique oak. It also tones down any white/pale Oak that has bee exposed by the sanding. A few hour and the stain is dry then three coats of polyurethane are applied with a sanding with 320 grit in between. Don’t other sanding the depression as we are putting a cork insert there.