Calling All Coopers

**woodhutt** · 25th January 2022, 05:48 PM

I've been asked to repair/reassemble a small oak keg that once contained bourbon. It had been left empty for some time and the wood has dried out and the keg fell apart when it was dropped.
{Don't be concerned - no liquor was spilt).
Luckily, there was no major damage to the joints and I've been able to get the staves back in the correct sequence for reassembly but I'm concerned about the two ends which are constructed from multiple pieces.

IMG_2418.jpg IMG_2420.jpg

You can see the joints in the photo but not readily apparent is that you can see daylight through the joints where they've separated.
I can't make out if the joints were originally glued without separating the pieces which I'm reluctant to do if I can avoid it.
So my questions are;
is there a way to draw the pieces back together with out separating them first and get a good seal once they are wet.
If I have to separate and re-glue, what adhesive do I use that won't be affected by (or, worse still, affect) the alcohol.
Any advice gratefully accepted.
Pete
.

**The Spin Doctor** · 26th January 2022, 10:30 PM

My guess is that was more a novelty barrel. I don't think traditional barrels used any glue, but those look to be glued. One way to find out is try to lightly break the joint. If it's only residue holding it together it'll break easy.

**Chief Tiff** · 26th January 2022, 11:23 PM

The heads should have been constructed with either dowels or loose tenons; not glued. They should be TIGHT. Where they fit into the staves look closely for a hardened paste that may have been used to help with sealing; the paste would have been made from ground linseed meal mixed with water. Good coopers didn’t need it though… When the cask was assembled the hoops would have been really pounded up tight forcing the staves together and gripping the heads. Once filled with liquid the wood would have then swelled slightly taking up any minute gaps.

If you’re concerned about leaks you can use epoxy to glue it all together as once cured it is inert and won’t react with either the timber or whatever beverage is stored within it.

**woodhutt** · 27th January 2022, 08:49 AM

Originally Posted by Chief Tiff

The heads should have been constructed with either dowels or loose tenons; not glued. They should be TIGHT. Where they fit into the staves look closely for a hardened paste that may have been used to help with sealing; the paste would have been made from ground linseed meal mixed with water. Good coopers didn’t need it though… When the cask was assembled the hoops would have been really pounded up tight forcing the staves together and gripping the heads. Once filled with liquid the wood would have then swelled slightly taking up any minute gaps.

If you’re concerned about leaks you can use epoxy to glue it all together as once cured it is inert and won’t react with either the timber or whatever beverage is stored within it.

Thanks for the reply Chief. I've taken another look at the heads and believe I can just make out what appears to be two small dowels joining the two pieces but no sign of glue residue. No glue was used on the staves whose mating faces are clean and, as you say, relied on hoop pressure and subsequent swelling to achieve tightness.
I'll have a go at separating the end pieces using a heat gun, cleaning the joints and applying glue only at the dowel locations then clamping firmly.
I did watch an Irish cooper giving a demo on barrel construction on YT. He said they sometimes used reeds to seal the joints around the edges of the end pieces but that a well-made barrel shouldn't need it.

Pete

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