My son asked me to make him a stave container for his basement hobby shop where he builds custom bicycles. It will serve a dual purpose as a waste basket and a leg for one corner of a wall mounted fold away work bench. The dimensions are 101cm or 39´1/2” tall and 30cm or 12” inside diameter.
It will be made from some cheap pine sold to be used for construction on cement forms. The wood dimensions are 15mm or slightly over 1/2” and a finished width of 7.77cm or about 3”. Here are the materials before cutting to length and width. I bought 16 meters or about 52-1/2’, enough to include a glued up bottom. see below
This could have been a real simple project. I could have just cut the required angles derived from simple coopering math, glued it together and left it at that, but not much fun, so I decided to hollow out the inside of the staves and round over the outsides so that it would be a smooth barrel once assembled. Not necessary for this project, but I was curious to see how close I could get it rounded and smooth on both sides.
Towards that end, I cut the staves to length and then decided to hollow them out using the coving technique on my table saw. This normally requires setting up a fence on an angle witch will give the sawblade the correct profile to cut the cove and then cutting it in 1/16” height increments, in my case two passes for each of the 13 staves needed. Here is the set-up. Normally the fence in photo 1 would be at a much less that 90 degree angle, but I had to go with 90 degrees because my saw blade diameter is so small (about 19cm or 7-1/4”). Photo 2 is shown with a workpiece see below
After much sawdust (on the table and on me) I got all 13 staves finished on the inside. I was pretty tired after this work and I’m glad it’s finished. see below
I also got the bottom glued up and ready to cut out on the bandsaw tomorrow. I still have to round the outside of the staves with a handplane and cut a dado near the bottom of each stave to hold the bottom piece. Lastly I will cut the edge angles on the staves which will allow gluing them into a circle. So still a fair share of work to go. I wouldn’t have minded just banding the staves together instead of gluing as it take a fair amount of glue to get the job done and it won’t be very easy to clamp either. see below
That is it for today. I blogged this just in case there is anybody out there who is thinking about making wooden stave buckets and is looking for an easy way to hollow out the staves on the inside. This work can also be done with a round bottomed hand plane, but with quite a bit more work involved. I will have to do the outside rounding with a hand plane. There would of course be much less work if a short bucket were being made.
Thanks for reading.
-- Mike, an American living in Norway.