Uploaded December 2023 | Updated September 2026, 9 hours ago
First butcher block build and possibly last.
24-lbs, 3-inches tall, 19.5-inches large diameter.
Purchased a Jack Daniel’s Whiskey Barrel from Lowes (falling apart - decorative purposes only at this point). Broke it down to the staves and hoops, had to remove some nails that had been installed to minimize it falling apart as it dried out and aged. Since the staves were curved in and tapered on both ends, these were cut down into 4- inch chunks that could be milled down.
The milling was the lion’s share of the work. Using my table saw elevated fence, I planed the proud side flat then turned the pieces over and flattened to 3/4-inch so each face was parallel. Then onto the table saw sled, the pieces were squared off on all four edges. Due to the different stave sizes and the tapers on the staves, these pieces were trimmed to about a dozen different width groups.
These were then edge glued into about 3-foot long strips. Then, after drum sanding even, these strips were stack glued together three deep.
After dry, these were milled to consistent dimensions and brought closer to the final 3-inch height, then cut into blocks for shaping. See my video on Hexagonal Blanks on Table Saw for more details.
The glue up of these hexagons was performed in stages to allow clamping and moving. A few red oak pieces were needed for the outside edges, I ran out of usable whiskey barrel. See my video Cut Obtuse Angles on Table Saw with Elevated Fence. The block was run through the drum sander many times to reach a consistent height of 3-inches. Orbital sanded to desired surface finish (600 grit).
One of the hoops was unrolled and peened on the short edge to straighten. These were then bent to compression fit around the block. Cut to length and holes drilled out to take advantage of the existing rivets. These were cleaned and then seasoned similar to cast iron using safflower oil. After the third heating, it was removed from the oven hot and fit tightly over the block and allowed to cool. Several holes were present for nails when it was made into a yard decoration. I used these holes, and a few new ones to install 2-inch forged nails for decoration and to prevent it shifting.
Finished with nearly a bottle of Howard Cutting Board Oil and then some Howard Butcher Block Conditioner.
First butcher block build and possibly last.
24-lbs, 3-inches tall, 19.5-inches large diameter.
Purchased a Jack Daniel’s Whiskey Barrel from Lowes (falling apart - decorative purposes only at this point). Broke it down to the staves and hoops, had to remove some nails that had been installed to minimize it falling apart as it dried out and aged. Since the staves were curved in and tapered on both ends, these were cut down into 4- inch chunks that could be milled down.
The milling was the lion’s share of the work. Using my table saw elevated fence, I planed the proud side flat then turned the pieces over and flattened to 3/4-inch so each face was parallel. Then onto the table saw sled, the pieces were squared off on all four edges. Due to the different stave sizes and the tapers on the staves, these pieces were trimmed to about a dozen different width groups.
These were then edge glued into about 3-foot long strips. Then, after drum sanding even, these strips were stack glued together three deep.
After dry, these were milled to consistent dimensions and brought closer to the final 3-inch height, then cut into blocks for shaping. See my video on Hexagonal Blanks on Table Saw for more details.
The glue up of these hexagons was performed in stages to allow clamping and moving. A few red oak pieces were needed for the outside edges, I ran out of usable whiskey barrel. See my video Cut Obtuse Angles on Table Saw with Elevated Fence. The block was run through the drum sander many times to reach a consistent height of 3-inches. Orbital sanded to desired surface finish (600 grit).
One of the hoops was unrolled and peened on the short edge to straighten. These were then bent to compression fit around the block. Cut to length and holes drilled out to take advantage of the existing rivets. These were cleaned and then seasoned similar to cast iron using safflower oil. After the third heating, it was removed from the oven hot and fit tightly over the block and allowed to cool. Several holes were present for nails when it was made into a yard decoration. I used these holes, and a few new ones to install 2-inch forged nails for decoration and to prevent it shifting.
Finished with nearly a bottle of Howard Cutting Board Oil and then some Howard Butcher Block Conditioner.
