CNC Barrels

[zorlack]

I run a High School theatrical scene shop and I need to make some barrels. They don't have to hold liquid, they just need to look barrel-ish.

My first dash at an attempt was terrible (http://farm5.static.flickr.com/4129/5083394151_d06ccd17d7.jpg). The lesson learned was: Spend more than 3 seconds thinking about the geometry.

Has anyone had any experience making barrels (or even fake barrels) with their bot?

-Dave

[erik_f]

Why not just make them flat and carve the look of a barrel into it?

[myxpykalix]

What you want is omething lightweight i'm sure.

How i would do it is this

For the top and bottom carve your circles like you did in the picture out of .5 plywood.

Then inset a dado .25 in thickness in a circle on the top and bottom for the staves to sit in.

Take a piece of .25 plywood and and cut your staves in it with a dado down the center that your internal ring can ride in.

insert staves in bottom
insert ring in center
bend staves and insert top of staves into top circle

The diameter of center ring will determine the shape of barrel
pin nail center ring from outside
you may have to bevel your sides of the staves on the tablesaw to make the staves fit better.

[zorlack]

Why not just make them flat and carve the look of a barrel into it?

They need to sit on them and use them as a step... Otherwise you're right, we'd just paint something flat to look like a barrel.

[dana_swift]

Dave- check into discarded whiskey barrels. They are made of oak, and must be thrown out after giving the whiskey the oak flavor. You may find one locally easier than making one.

It helps if you live in a state with a distillery of course..

What state are you in? Your profile doesn't say-

D

[michael_schwartz]

I suppose one way may be to make a simple but sturdy frame with MDF or plywood similar to what you have, and use a 1/16" to 3/16" thick shop sawn veneer to imitate the staves.

Another may be to do a little bit of reading up on coopering and give it a shot. Cutting the staves on the table saw would likely be a better option.

[jdervin]

Dave--

For a show we did a few years ago, we used large plastic barrels (can't remember what they held originally, some sort of chemical if memory serves) and scene painted them to look like barrels. It was surprisingly effective. Even had them on stage with some actual barrels. I'm at home right now, but could take pictures and share them if you want.

Of course, they weren't done with the 'Bot. I think a true barrel (non-cylindrical; the kind that bulge in the middle) would be prohibitively time-consuming to cut via CNC.

Any chance you're near Maine? If so, I'd be happy to loan ours to you.

[shoeshine]

Dave,

actually you are on the right track in your build. The difficulty is getting the shape of the stave out of thin ply. I would however reccomend 5 internal supports as traditional barrels have 4 coops, the metal rings that hold the thing together (both ends and somewhere down each arc. see pic.)

attached is a dxf of a stave for a barrel with end dia. of 12", middle dia. of 18" and 24" high (like a pirate ship powder keg) you would need 24 of them.

Give me your dimensions [end diameter, center diameter, height, + height at which you would want the coops.] and I can calculate a stave for you to cut.