We were contracted to design and build two (identical) signs for a bar in KY. Using the barrel ends was a no-go because the client wanted a little bigger in the diameter. So we bought a barrel, and I “faked” the ends by cutting out of the middle.
I had to build the stand for the barrel to sit level and spin for easy cutting. With my two “ends” cut out, I routed out two circles in Oak Ply and secured them with brackets from behind. Then layered it with pieces of sentra (ring, letters, horse/jockey).
They came out great, client loves them. The last picture is a shot posted on Cincinnati.com. You can barely see the sign hanging behind the bar (on the right).
It seems going for a beer and looking at my handy work is in order.