The Headboard Project

The Headboard Project

I began this project after many years having that “free” gold plated aluminum headboard adoring our bed and finally removing it about a year ago.  Since I work with recycled wine barrel wood I adapated the design from the garden bench and created a unique result.

I purchased the barrel a special type made by Seguin Moreau they produce a barrel using thinner staves conserving the French oak raised for barrel production.  The barrel had been used by Canoe Ridge Vineyard in Washington for the production of Merlot wine. The thinner staves made it lighter and more flexible.

Step One:

I disassembled the barrel this process takes a bit more work as this barrel design has a support board across the head and the bottom and is held in place by wooden pegs. I was careful to preserve the top and bottom for later use. Once this was done I cut the hoops and then with a little help from a mallet the staves are separated from each other. In making barrels there are matched pairs in width and I sorted these out. Staves vary in width from one to five inches. The back side (see photo) is stained a beautiful burgundy red.

 

I am often asked it must be great to smell the wine, it is a yes and no answer , if the barrel has been cleaned properly after the wine has been removed and stored in a cool dry place the aroma is wonderful, but often it is not as mold often grows if not properly treated. This is why I am very selective in where I purchase barrels.

 

Step Two

Design: I measured the bed with and then determined that I would need a 72 inch wide head board I laid out the staves starting with the bung hole stave in the middle and added staves one each side staring with the wider ones and progressing to the narrow ones on the outside. I wanted to mimic the back of the “Garden Bench” and have the length progressively shorter.I made a cut list and used my chop saw to cut them to the correct length. Note: French Oak used in wine barrel construction is as hard as Rosewood so you the proper cutting and finishing tools.  Then I sanded them with an orbital hand sander using 80,220, and 320 grit. My goal was to remove the crud and keep the character of the wood. I did a dry fit layout and made a few adjustments. Then pre-drilled the holes using a countersink bit.  Now it was ready for stain

Step Three

I use Cabot Stain, I wanted to use a color that would contrast well with the colors in the bedroom. After several tests and approval from my wife I selected Ebony. The darkness was achieved, but still enhanced the grain of the French oak. I apply it with a rag and wipe off excess after sufficient drying time I applied the first of three coats of semi-gloss Minwax^® Fast-Drying Polyurethane sanding between each coat. After proper drying time I was ready for installation.

Step Four

I located the studs, after the usual hunt and fish process. What I can’t understand is we can go to Mars, but there is no tool that can accurately find studs in the wall at any price. As usual there was one stud not in the right location but I was able to secure the 1 x 4 red oak board which I stained to match. I began attaching the staves on the left working my way across until all 23 were attached. I was careful to make sure the staves were straight and lined up correctly. One the bed was slid forward into place the final result was a unique headboard. I have been thinking of ways to create additional features check back and see those results.  

THE HEADBOARD PROJECT COMPLETE

Sweet Dreams Everyone

Robert

Renewable Resource Wine Barrel Wood

I have been asked many times why use wine barrel wood? Especially by my more traditional woodworking friends. Yes there are times when “new wood” is better, but then part of every wood workers soul is to create something unique. Over the past five years since I began working with wine barrel wood I have created many different items and while they don’t always look like my first concept all in all they have more than met expectations. I am continually learning how to use the three basic components; the head and bottom, the staves and the metal hoops. Along with the corks and bottles the list of ideas has grown to over 100.  I started out just making candle holders that people have been producing since the 60’s. In looking back to my roots barrels or tubs were one of the primary items my Great-Grandfather built in the late 1800’s and early 1900’s for the people of Western North Carolina. I am fortunate to have one of his 5 gal tubs, unfortunately in my curious youth I took it apart and just recently began the process of reassembling it once the water re swells it I will post a photo. It is still amazing that he built this with hand tools and from memory. I remember asking my grand father did Grandpa Davis have things written down and he said only who had ordered it and what size and the price. From talking with relatives I heard many stories of how he challenges anyone to prove that the tubs didn’t hold exactly the amount he said they would.  Here is a photo of the house he built that now resides in The Smokey Mountain National Park Farm Museum near Cherokee, NC

 

 

 

 

 

 

 

 

 

 

 

Recycling was not my original purpose. I just appreciated the quality of the wood. Cooperages raise the oak like a crop and only 1/3 of the wood harvested passes the grade to be made into barrels. There are no knots in the wood which is great as working around knots can be frustrating and sometimes cause the failure of a project. The other main reason is the uniqueness of each piece of wood. I have worked with over 1,000 barrels and no two are alike, just as the wine contained in them. IKEA does an excellent job of mass producing items; I want to create things that are unique and durable as well as functional. The current cost of a new barrel, even from Hungary is well over $800 and to just make them in to planters seem such as waste. I would say 70 percent the ideas from me, but the other 30 percent come from customers and translating their ideas into reality is one of the more exciting projects I do.

Future posting I will share the different process involved in making these items. Including a “foot spa”

 Robert

WWC