|Project by BGW||posted 09-05-2014 01:09 PM||3004 views||8 times favorited||14 comments|
This job has been a long time coming…about a year ago (last November to be precise), I was approached by the owners of my favorite Brew Pub in my home town to remodel their bar. We got creative with ideas, and I came up with the Bourbon Barrel idea with a Black Walnut live edge bar top. They loved it…so over the next several months I set about finding the barrels that would match, and selecting logs to be ripped.
After picking some beautiful walnut at a local mill and having them cut it to 3.5” thick, I then found a kiln. It took about 45 days to adequately dry the lumber. In order to flatten the top surface, I built a sled that would allow each slab to fit. We used a router with a 1” bit (probably should have gotten a bigger bit, but we were taking so much material off in certain spots that I didn’t want to risk damaging the nice top). After the rough-router planing, we belt sanded with 80 grit and finished up with 120 grit on the orbitals.
Finally, it was time to lay out the ‘puzzle’ pieces to match up the grains. This was tedious and required a lot of moving around the big pieces (after drying, they were between 2.25-2.5” thick, and 6’-8’ long). I used a pocket hole process to seam the joints. The finish is a high gloss Epoxy, which makes the bar pop. I couldn’t be happier with the finished product…and the owners are over the moon. Thanks for looking…I may post more pictures of the logs and our milling process below.
You may notice the carving on the half wall too…I carved that logo into the extra barrel tops. There are three such signs in the bar.
-- Bob, Indiana, "Well done is better than well said." -Ben Franklin http://www.bgwconstructionllc.com/