WHAT MAKES IT WORK? #8 Making Whiskey Barrel Staves tubalcain mrpete222

This is how wooden barrel staves are made.
Watch all the videos in this series.

[@grizzlydan8]

An historical picture, A video of the process, and live demonstration in miniature. You must have been one heck of a good teacher to have. And now I enjoy your instruction. Thank you Tubalcain.

[@mrpete222]

+dan andy Thanks for watching

[@VintageMachinery]

Cool Stuff. We have a Peter Gerlach Stave Mill very similar to that one at our museum here - the Georgia Museum of Agriculture. We did a restoration on it back in 2008, but it is still awaiting some finishing touches before we can use it. Our stave mill was likely making staves for turpentine or rosin barrels for the naval stores industry which was really big in South Georgia back in the late 1800's through mid 1900's. Our museum also has an operational wood fired turpentine still which we run each spring - and which we have to make a bunch of barrels for in preparation!

[@garygsp3]

+Keith Rucker - VintageMachinery.org Keith the next time I get any where near Georgia I'm going to have to stop at that museum. Then again that might be a bad thing they might not get me to leave.

[@SuperBowser87]

I was thinking of you when I watched this. Being in Kentucky I see a lot of these whisky barrels.

[@mrpete222]

+Keith Rucker - VintageMachinery.org Awesome Keith--hope to get there some day

[@JackHoying]

+mrpete222 Luckily, I'll be there this coming Saturday! Driving down to meet Keith and see the museum while on our way to a weeks vacation in Florida.

[@mrpete222]

+Jack Hoying I need to visit as well

[@simpleman283]

I thought this video would have had so many more views. I wanted to see the bicycle coaster video again and just started watching the full playlist What Makes it Work. This has been a very enjoyable series.

[@mrpete222]

Thank you very much, I stopped making more videos in this series Simply because there does not seem to be much interest

[@MrThisIsMeToo]

Thanks for sharing. Very well done Mr Pete!

[@mrpete222]

+MrThisIsMeToo thanks for watching

[@MrLarry0001]

Great video! I've been to a cooperage and have seen the barrel assembly process, but the staves were obviously already cut and shaped. So thanks for showing what happens prior to the cooperage. Great story at the beginning of the video as well.

[@mrpete222]

+MrLarry0001 Thanks--I think they buy all the staves from a dedicated stave mill

[@danbreyfogle8486]

Very interesting Mr. Pete, I had no idea how they were made.

[@hermit3400]

Always great to see how things are made.

[@mrpete222]

Thanks

[@jamesmorleyjmor5003]

great vid didn't know barrels were made that way its all aluminium now nice to see some one keeping the craft going very few coopers left now cheers mr pete.

[@mrpete222]

+james morleyjmor Thanks for watching

[@rickswazey9472]

Very interesting, Mr. Pete, thanks for sharing. All the best, RS

[@mrpete222]

+Rick Swazey Thanks for watching

[@MrToolsinbox]

Very informative. Great quality video in a old school art. Thanks very much again Mr. Pete.

[@mrpete222]

+MrToolsinbox Thanks for watching

[@daki222000]

nice video. Worth mentioning is perhaps that all the wood is sawed perfectly quartersawn this way, which is a important for good barrels. Cheers.

[@mrpete222]

+Flip de boer Good point

[@ALUMATRIX]

that was cool!! i enjoy all your videos,,, keep'em coming ! i always learn something new!

[@mrpete222]

+ALUMATRIX Thanks for watching

[@ThePara7]

I wait for videos like this great job and thank you for your time and effort

[@mrpete222]

+GEORGIA-PREPPER Thanks for watching

[@mikeadrover5173]

Hi Mr.Pete and to Keith, who does not like a good road trip. Like ~M~

[@mrpete222]

+Mike A Drover Thanks for watching

[@johnlangell9512]

These videos are great, Mr. Pete. Where else can one learn this kind of stuff? This particular one is an example of something I wish I had been shown as a boy. Your explanatory style is very enjoyable. Keep it up!

[@mrpete222]

Thanks

[@Hearthman1159]

Can you make a video demonstrating how to rivet the iron bands on a wooden barrel? Love your vids.

[@pamtnman1515]

Hearthman1159 the riveted bands are slid over the staves and held on by friction and tension. It’s an art.

[@jimmydiresta]

amazing to see this machine!! so sad to know many of the old ornate industrial matches used in the making of barrels in the last 100-150 years are lost for ever.

[@mrpete222]

+jimmydiresta Lots of machinery scrapped during WW2

[@comictrio]

+jimmydiresta There is really nothing like vintage, industrial machines. I love the engineering and craftsmanship put into them, and the machine tools that created them. I spent 2 years rebuilding 20 Saco Lowell textile spinning machines.These 20 machines were retrofitted long before I was born to spin paper for weaved paper vegetable bags. Not one of these machines was dated older then 1929 and the oldest was made in 1925. I learned to machine replacement parts for these machines. Before I took the job I had never touched a lathe or a milling machine. By the end of my first month on the job I was turning treads on an old South Bend 9 inch lathe and milling parts on a Bridgeport milling machine for these old machines. Thank God for The Starrett Book For Student Machinists. About one year after I finished rebuilding these machines, the market for the products created on the machines had died and replaced with plastic knit bags.The company decided to disassemble and scrap all 20 machines. The workers that ran the machines before stayed on long enough to take the machines apart. I trained the people to disassemble only 2 of them. I saw these machines as a part of American history, and I'm a huge history buff and very nostalgic as well. I put in 2 years of hard work, sweat and blood into rebuilding them, so I was very sad to see them destroyed. This happened nearly 30 years ago. I am grateful to have been given the opportunity to rebuild those machines, and I learned so much in the process.

[@mrpete222]

+comictrio Thats a great story. I used that starrett book in my shop classes

[@mrpete222]

+jimmydiresta Yes it is. Did you ever go to the AMERICAN PRECISION MUSEUM in Vemont. They have a website. I haven't been there yet

[@jimmydiresta]

+mrpete222 no, perfect reason for a road trip!!

[@stevenacarter77]

thank you mrpete222 that was Cool

[@mrpete222]

+stevenacarter77 Thanks for watching

[@fordtruck193]

I thought you were going to walk off with one of those staves from the tent-just for old times sake! I also thought a Bridgeport would automatically reject a piece of tree! :) Enjoyed the vid as always!

[@mrpete222]

+Tad A Too splintery

[@TractorWrangler01]

Don't know what to say that hasn't already been said so.. Great Video! would have like to have seen the other operations though. Especially on the hole saw in your shop! Mini barrels for all kinds of stuff!

[@peterwynn4088]

I would like to know how the saw sits on its bearings and how the power is transmitted from the belt to the drum! I can't figure it out from the video.

[@mrpete222]

+Peter Wynn I really do not know

[@squensler]

Good Video; as a home distiller ; whiskey barrels are made of American White Oak only and charred on the inside, aging in these is what gives distilled spirits its color and flavors, all distilled spirits are transparent and have little flavor out of the still. Good White Oak barrels are also very expensive.

[@mrpete222]

+Dennis Clos Thanks for watching

[@ffslave]

Interesting thanks for sharing.

[@mrpete222]

+ronnie coursey Thanks for watching

[@juanrivero8]

Very interesting. So they made the round inside with a great big hole saw. But then the staves have to be beveled to make the barrel round. How did they do that? I have made a 15 cm high (6") by hand and I arranged things so as to get 6 staves to the barrel. Nice easy angle. Do it with a spokeshave. But they must have had some kind of machine to cut the bevels?

[@mrpete222]

+Juan Rivero thanks for watching

[@jimadams8182]

I won't make a bung hole joke, but I will say for me shop class was the only good thing about school. I used to get along best with my shop teachers. In my day they were all knowledge and no bull!

[@mrpete222]

+Jim Adams Thanks for watching--yes, and we teachers liked kids such as you. They came early & stayed late

[@cougarhunter33]

+Jim Adams I was the same way. The only reason I showed up every day was for woodshop.

[@longcaster]

Jim Adams, did you enjoy being inside the barrel or outside of it?

[@tetekofa]

Yes, who remembers the ole Swiss St. Bernard rescue dogs with the One Gallon Barrel of Brandy around its neck?

[@garyc5483]

+tetekofa I think you will find that story is nothing but a myth Although in legend casks of liquor were strapped around the dogs' collars to warm up travelers, no historical records exist that document this practice. Even a big dog like a ST Bernard would not walk very far with a 14 pound keg around its neck. .

[@mrpete222]

+tetekofa Thanks for watching-I do

[@marbleman52]

My Grandfather owned a stave mill here in Batesville, Arkansas, back in the 1930's. I was told that he kept a lot of men working during the Depression so they could feed their families. The stave mill has been long gone for a long time. Thanks for the memory reminder.!

[@mrpete222]

+marbleman52 Thanks for watching

[@JeremyMcMahan]

Fantastic info. I'd be interested in seeing the rest of it... How do they get them so tightly into the rings? Do they steam bend the staves for assembly? Etc. etc. Amazing stuff. Thanks Mr. Pete 222!

[@cougarhunter33]

+Jeremy McMahan They put the rings on hot, and the rings shrink as they cool. At least that's what I believe I have seen before. I think they iron-banded wagon wheels the same way.

[@KingNast]

There was an episode of Dirty Jobs where they showed the whole assembly process. It's probably on KZbin. I think they squeezed the staves together with a loop of cable, then put a heavy steel ring around it. Then they put the flat bands on

[@mrpete222]

+Jeremy McMahan Thanks for watching

[@mrpete222]

+KingNast I saw that one

[@KingNast]

mrpete222 That was a great show.. I was sad to see it canceled! Haven't really seen much of his new show. Couldn't really get into it

[@MrStacygordon]

Hello Mr Pete:I did this to my Lathe,And it makes the 3 jaws More Accurate

[@mrpete222]

+MrStacygordon thanks for watching

[@butchbernaitis7834]

I love it

[@mrpete222]

+Donald Bernaitis Thanks for watching

[@SSArt98]

Very interesting, thanks!

[@mike97525]

thanks

[@mrpete222]

+mike97525 Thanks for watching

[@Opinionator52]

Gives me an idea for some mini treasure chest lids and various small straight sided things! Thank you Tubalcain.... Take care! :o) O,,,

[@mrpete222]

+Opinionator52 Thanks for watching

[@millomweb]

Is it a hole saw ? No, it's not even half a saw !

[@DaddySki87]

Originally from Elgin, IL here. Love your show. Keep up the great work. Became Machinist in Army for 4 years then went into Army communications for 6 (what a mistake haha). Anyways love what you do.

[@springwoodcottage4248]

Spanish Armada (1588) had poor barrels because Sir Francis Drake torched over 1600 tons of staves (enough for 25,000+ tons of provisions) in raid on Cadiz in 1587, famous "Singeing of the beard" & in subsequent attacks on supply routes.

[@mrpete222]

+Springwood Cottage Thanks for watching

[@marksinden4156]

there's a British Pathe film on shaping the staves dating from 1949 if you search on KZbin for 'shaping barrel staves' - shows the bevelling etc using a small axe.

[@mrpete222]

+Mark Sinden Thanks-I really enjoyed that

[@bendavanza]

Thanks for the demonstration. I always wondered how they were first formed. Cooperage is an art kept alive by the law concerning bourbon must be aged in new charred oak casks. This brought about a demand for purchasing used American oak barrels to age other liquors.

[@mrpete222]

+bendavanza Thanks for watching

[@jonsweeney7684]

Thanks for the video! My brother split white oak stave bolts when we were in college and I've always wanted to see how the staves were made! Work was hazardous in those days. Two one-armed men I've known had lost an arm in stave mills. Both of them would be in their late 80s or 90s by now.

[@mrpete222]

+Jon Sweeney Thanks for watching--wicked machine

[@Lee-qp6gf]

I always admired wood barrels but never thought how they made the staves. Cooper trade was very interesting. An awful lot to it.

[@mrpete222]

+Lee Waterman Thanks for watching

[@adamkeys1586]

you mentioned more work to be done for the rest of the barrel. could you make videos with. breaking the sides.

[@jamescampbell7780]

Be good to see the next stage in the process!

[@jblistener7491]

Great stuff, as always! Enjoyed the photo and story about your "borrowed" staves. Never actually thought about how they were made, but now I'm inspired to make a couple of small, decorative barrels, as my fiancee loves that sort of thing. :)

[@mrpete222]

+jb listener Thanks give it a try

[@mikec.1259]

I made wine with my grandmother back 30 years ago. I always marveled at the two oak barrels she used. It's nice to see how they made those things. One of your more interesting videos, Hats off to you!

[@mrpete222]

+Mike C. Thanks for watching

[@marksinden4156]

A few years ago I was out of work following redundancy, and one of the guys I met while job hunting was a rum barrel maker from Jamaica. I knew how they shaped the staves once cut, but was unaware how they formed the curved stave blanks. Thanks for the very interesting video.

[@mrpete222]

+Mark SindenThanks for watching

[@marksinden4156]

Always interesting to watch your videos. I'm a 'general' engineer I guess - a real hodge-podge of electronics, software, sheet metal and machine work. A real mixed background which is why your own mix of topics is fascinating.

[@davida1hiwaaynet]

Excellent! I had never thought about how they made barrels. Amazing machinery at the steam show - that saw looks like a beast that you better know how to use it or it will use YOU instead!

[@mrpete222]

+davida1hiwaaynet Thanks for watching

[@robertklein1316]

Mr. Pete, Thanks for the vid. I remember everything came in barrels e.g. nails,cement, bolts, etc., try putting that in your shopping cart today.

[@mrpete222]

+Robert Klein Yes-we used to play with the wooden kegs

[@just_a_guy_doing]

Thank you for teaching me about barrel staves. never knew that's how they were done... keep the videos rolling... always learn something from them that I can use in the shop/classroom.

[@mrpete222]

+QuainBuilt Thanks for watching

[@AdrianHiggins83]

would like to see a small one made.

[@alexantonov4129]

+Adrian Higgins And then a special Tubalcain Whiskey made in it

[@mrpete222]

+Adrian Higgins Thanks for watching

[@kevinholbrook7174]

I would like to know more about how to make the tapered and the beveled edges of making the staves. Please upload a video of doing this process! Thanks 🙏

[@patrickbabcock7679]

3yrs later, wonder, did u ever make those little barrels? That'd be cool. Love ur stuff!!!

[@kenzpenz]

I love this stuff. This has been a learning experience for me indeed. Never really put much thought as to how they made those barrel staves. I remember as a kid getting talked into making skis out of a couple of barrel staves and attaching them to my boots with canning rubber rings. Well they lasted until the first contact with the snow, and down I went. Tough growing up poor, but managed to survive. I have watched a couple of videos of how they assemble the barrels with all the parts. That might make a great follow up video. Again thanks for another great video....from Ken...the old guy.

[@mrpete222]

+Kenneth Bartlett Thanks for watching. I had a pr of used wooden skis with leather straps. Could not keep them on

[@emtffzartman666]

That is very interesting. Never really thought into the barrels needing to be made that way. That is an impressive machine they use! Great video!!

[@mrpete222]

+Reenactor Guy Thanks for watching

[@alnglenn]

What kind of machine is used to cut the curves and bevels on the edge of staves?

[@4437dags]

Can't say I've ever given it a thought, but any day without learning something new is truly a sad day. Thanks for the lesson in a fascinating dying skill.

[@mrpete222]

+Darren Harvey Thanks

[@FredMiller]

Great video Mr Pete. Thanks for sharing...

[@mrpete222]

+Fred Miller Thanks for watching

[@millomweb]

It's not tubular cain but tubular saw.

[@pappabob29]

Out here in the Napa Valley there is a Cooperage by the name of Sequin Moreau. Located right on Highway 29 on your way to Napa and the rest of the valley. It's open for tours where you can watch them assemble and test the barrels. Truly fascinating to watch this old world skill even it "modern machinery" has replaced some of the skill that used to be required. Nice video here showing the process. The wooden barrel is truly a work of art. kzbin.info/www/bejne/eKC9Z6Vue9VpodU

[@mrpete222]

+Pappa Bob Thanks for watching

[@bestfriendhank1424]

How did I miss this video when it first came out?

[@millomweb]

"Short and sweet" as they say :)

[@adnacraigo6590]

Very interesting sir.

[@zpoppe]

wounderful video, very interesting

[@mrpete222]

+zpoppe Thanks for watching

[@indianchief741]

thanks for the video!

[@mrpete222]

+indianchief741 Thanks for watching

[@hankmerkle5928]

SO cool that you were at the Stephenson County Antique Engine Club Show in Freeport IL! As we have discussed in e-mail, I grew up in Freeport, so it was nostalgic that I go to see the barrel staver on a YOU video in 2024 that I have seen in person so many years ago!

[@mrpete222]

👍👍 my wife grew up in Freeport

[@indianchief741]

looks like a big hole saw!

[@mrpete222]

+indianchief741 It is. Thanks for watching

[@ohiorivercats]

I have heard my dad talk about cutting staves when he was a kid, ( born in 1936) I know they didn't have a stave saw on the farm and I never really asked but I always supposed they were just cutting white oak stave blanks to sell. I seem to recall .03 or.05 cent each maybe. I still have granddads old fro & draw knife? I think its called a fro?? that he used for shingles and staves and hickory axe handles.

[@mrpete222]

+Ohio River Pilot Yes--just the blanks

[@indianchief741]

IT IS!

[@mrpete222]

+indianchief741 Thanks for watching

[@JeffreyVastine]

Another interesting video Mr. Pete. The same method could be applied to drum making and in particular congas and bongos, which makes this another video that wll be of benefit to my youth outreach. Thanks!

[@mrpete222]

+Jeffrey Vastine Thanks for watching.-yes it could

[@1jtolvey]

BARRELS FOR BOURBON WHISKEY ! ----- WHY ??? BOURBON BARRELS USED (( 1 )) TIME ONLY , EVERYONE ELSE BUYS USED BOURBON BARRELS .

[@mrpete222]

+OLD WIPPER-SNAPPER Thanks for watching

[@darrenmartin2195]

Excellent and informative as always. Are you going to finish that little 50.8mm barrel? Thanks.

[@mrpete222]

+Darren Martin Thanks for watching

[@pjhalchemy]

Thanks! Learned a lot. Had no idea it was a hole type saw...always thought they used some milling/sanding technique for the curves.

[@mrpete222]

+pjsalchemy Yes-and that was invented 15o yrs ago

[@Tryin2FlyII]

I get a feeling we are going to see some very nice little Decretive and or Functional barrels from some of the viewers (At least I hope we do) in the very near future-Great video! mrpete

[@mrpete222]

+Rosario W Thanks for watching

[@JackHoying]

I intend to do a tour sometime, but the Brown Foreman Distillery in Louisville makes their own barrels for Old Forrester bourbon (a favorite of mine). They have a nice video of it at kzbin.info/www/bejne/anO2haB7ibajaNE

[@mrpete222]

+Jack Hoying Thanks for watching

[@JackHoying]

+mrpete222 I had never seen a drum type saw like that and hadn't given it a thought that they used such a thing. They definitely would save 15 or 20% of the log, rather than cutting it flat and planning it to the curve later.

[@countrycraftsman5110]

Great field trip. I marvel over the guiness of are fore fathers. Today we can copy in some fashion or another to come up with equipment but those men came up that stuff off the top of there head. Mother of necessity indeed.

[@mrpete222]

Yes

[@kevinwillis9126]

love seeing how things were made back in the day how times have changed.. thankyou mrpete most interesting..

[@mrpete222]

+Kevin Willis Thanks for watching

[@comictrio]

You could make a bunch of complete mini barrels. You could be a mini cooper. Bad pun intended :)

[@mrpete222]

+comictrio Thats a good one-mini cooper

[@hellrocker1212]

Just got done watching the how its made on barrels and was hoping to learn more. well beholding to me youd upload this right as i was looking, thank you and keep it up man.

[@mrpete222]

+hellrocker1212 Thanks for watching

[@1musicsearcher]

A 2 inch barrel? That's just the size needed for aging a double shot of whiskey!

[@mrpete222]

+1musicsearcher Thats a good one!

[@dictare]

Thank you Tubalcain. One more thing I'd like to try.

[@mrpete222]

+dictare Thanks for watching

[@ClaytonwFirth]

How would they form the taper on each stave? I assume that this wouldn't be a manual operation.

[@mrpete222]

+Clayton Firth Thanks for watching

[@mainengines]

Love the LEARNING, you all provide.

[@mrpete222]

+Joe Rogers Thanks for watching

[@62forged]

We need more fairs in New England with this kind of demonstration.

[@mrpete222]

+Toolrific the old craftsman are dying

[@darwinvoncorax]

There's no such thing as, "More than I want to know..." :)

[@mrpete222]

+Darwin von Corax Thanks for watching

[@performancepursuit]

another great video. many thanks

[@mrpete222]

+performancepursuit Thanks for watching

[@cheesywheeler8322]

Man you are a good hand i.e. A great craftsman and that's coming from a busted millwright

[@stevedotrsa]

Needs 2 thumbs up....

[@mrpete222]

+stevedotrsa Thanks for watching. Thanks for watching

[@MrJgstoner]

Thank you, sir.

[@mrpete222]

+MrJgstoner thanks for watching

[@Toolman22364]

Now that's a hole saw there.

[@mrpete222]

+Toolman22364 Thanks for watching

[@warrenfromga9945]

Very interesting. Thank you.

[@adrianhanson9584]

Wow! Thanks for that, you learn something every day

[@tolydukhovny682]

thank you, mr. peterson, for the video! there's always something new to learn here. could a larger saw be fit into that machine? or is it a dedicated machine to a particular barrel size? -toly

[@mrpete222]

+Toly Dukhovny Thanks toly. I bet its dedicated

[@garyc5483]

Another excellent tutorial mrpete and a road trip as well. Thanks for sharing and long may it continue. regards from the UK

[@mrpete222]

+Gary C Thanks for watching

[@MrGoosePit]

I love it when you go out and film the machinery at those shows. Very neat to see the stave cutting machine at work. Thanks Mr. Pete!

[@mrpete222]

+MrGoosePit Thanks for watching

[@1973mre]

Once again thank you for this great series I have followed you for a while and this series I really enjoy

[@mrpete222]

+1973mre Thanks for watching

[@headwaters362]

Awesome!! Thanks so much for such a great demonstration.

[@mrpete222]

+Headwaters Thanks for watching

[@jason-ge5nr]

well, I learned something today. Thank you Mr Pete.

[@mrpete222]

+Albion Laster Thanks for watching

[@patrickwhitehead7584]

I grew up in Freeport. The threshing show is really really great. The silver creek museum as well.

[@patrickwhitehead7584]

Something you might have also seen is the Mystic Seaport in Mystic, CT. It's a bit like Greenfield Village at the Ford museum. There's lots of extremely interesting things there, including a cooperage and working shipwright's shop.

[@mrpete222]

+Patrick Whitehead My wife grew up there. Been to the Mystic, but its been over 40 years

[@patrickwhitehead7584]

+mrpete222 wow. Small world. That's actually where my entire family is from. My dads first job out of the navy was in a machine shop at electric boat.

[@mrpete222]

+Patrick Whitehead My father in law was at fairbanks morse

[@patrickwhitehead7584]

+mrpete222 now that's a great old company from, WI. Beloit, I think. Dad was an electronics tech on the George Washington Carver, a submarine, and told about running those opposed cylinder diesels while they were on the surface. He says that he loved looking at them- dual opposed cylinders with crank shafts on top and bottom. What he tells of is sitting at his station, while the diesel was running, and there was a flap on the intake which would close when it detected water in order to avoid sucking sea water into the engine. When he flap closed outside the boat, another flap would open inside the boat so that the engine could still have intake air and avoid stalling. When the intake inside opened, he says that everyone would flinch simultaneously as their ears popped from the corresponding drop in ambient pressure. As a diesel mechanic, I would just love to see one of those engines!