CURRENT BUILD
From Bourbon Barrels to a Finished Room
It started with three bourbon barrels and an empty wall.
Rather than simply adding a bar to the room, we're designing and building the entire space around the character of the original barrels.
Along the way, we're documenting the decisions, experiments, mistakes, solutions, and craftsmanship that turn an idea into something real.
Follow the build from the beginning.
DESIGN- MATERIALS-BUILD-FINISH-INSTALL
Chapter 01: The Starting Point
It Started with The Barrels
We started with three authentic bourbon barrels—weathered, marked, and carrying the character of their previous life. Rather than treating them as decoration, the goal was to make them part of the architecture of the room.
Before anything was cut, we studied the barrels, measured the space, and began sketching ways the cabinetry could be designed around them—not simply added beside them.
Chapter 02: The First Idea
From a Sketch to a Plan
Start with a problem and the idea. Refinement comes later
The first version wasn’t created in CAD. It started with a pencil, a piece of paper, and an idea.
The barrels established the character of the room, but the challenge was figuring out how to make them feel like part of a finished space. This early sketch began exploring the proportions, cabinetry, shelving, and how the barrels might fit into the overall design.
It wasn’t a finished plan—and it wasn’t supposed to be. It was simply the first step in turning an idea into something we could build.
Chapter 03: Understanding the Materials
The Character was Already there
Sometimes the material should influence the design, rather than the design forcing the material to change.
What We Wanted to Preserve
Before deciding what to build around the barrels, we took a closer look at what we already had.
The markings, worn oak, darkened steel hoops, stains, dents, and imperfections weren't things we wanted to hide. They were part of the barrels' history—and part of what made them worth building around.
That led to an important design decision: Don't make the barrels conform to the new cabinetry. Design the new cabinetry to complement the barrels.
Chapter 04: Designing The Space
Making Three Barrels Feel Like One Design
Left: Early Design Concept | Right: Refined concept sketch (Work in Progress)
Three barrels. One unified design.
The challenge wasn't simply finding a place for three authentic bourbon barrels. It was designing an entire built-in bar around them while preserving the character that made them special in the first place.
Each barrel carries its own history in the markings, aged oak, and steel hoops. Rather than hiding those details, we wanted to make them the centerpiece of the room.
The design began evolving around custom white oak cabinetry, integrated bottle displays, concealed storage, and functional barrel doors. Every element needed to complement the barrels without competing with them.
As the design continues to develop, we're balancing appearance, functionality, and craftsmanship—turning three individual barrels into one cohesive installation.
The goal isn't just to build a bar. It's to create something that looks like it has always belonged in the room.
Chapter 05: Selecting The Materials
Choosing the White Oak
We wanted the cabinetry to complement the aged bourbon barrels, not compete with them.
White oak offered the grain, strength, and character we were looking for. Rather than starting with finished lumber, we selected rough-sawn boards that we could mill and prepare ourselves.
The material selection was more than a shopping trip. Every board needed to contribute to a finished bar that would feel like it had always belonged in the room.
The next step would be turning that rough lumber into the components of the build.
Chapter 06: Giving the Barrels a Second Life
Building the Barrel Doors
Preserving the Curve. Creating Something New.
Turning the original bourbon barrels into functional cabinetry presented an unusual challenge: creating doors without losing the natural curvature and character of the barrels.
Rather than replacing the curved staves with flat panels, we carefully prepared the original wood, joined the individual staves using biscuits and wood glue, and clamped them together to form three curved door panels.
The goal was simple in concept, but demanding in execution: each door needed to follow the shape of its barrel while opening smoothly and preserving the appearance of the original craftsmanship.
With all three door panels assembled, the next steps are final fitting, hinge installation, and finishing.
Sometimes the best design solution isn't changing the material. It's finding a way to work with what makes it unique.
Chapter 06: The Details that Make it Work
Fitting the Barrel Doors
Follow the Bourbon Bar Build
Follow along as three authentic bourbon barrels provide the foundation for a custom-built dining room. Get updates on the woodworking, design decisions, challenges, and craftsmanship as the project takes shape.