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3. Next, scribe the lines for the opening in the barrel making sure to
round the corners slightly. Drill a 1/4" hole somewhere along one
of the lines to start the saber saw. If your barrel has ribs, as most
do, you will have to cut a 1" vee notch on each rib to facilitate
opening the door. Attach the hinges and the hasp to the barrel and lid
using 1 x 1/4" stove bolts.
4. From 3/4" white pine, cut two circles 7 1/2" in diameter and two circles 2 3/4" in diameter. Drill a 1/2" hole in the center of each and apply glue to the 2 3/4" circles. Glue the 2 3/4" circles to the 7 1/2" circles. This can be done easily if the circles are temporarily slipped over the 1/2" steel rod and clamped. After the glue has dried, remove the disks, insert the rod through the barrel and assemble as shown in the illustration, using four 1 1/4 x 1/4" stove bolts in each.
5.To build the support frame, cut the 2-by-4's to length and, using a corner lap joint, assemble with two 1 1/2" #10 wood screws in each joint. The uprights will also have to be dadoed 23 inches from the bottom to accept a 1 x 3" board. To make a corner lap joint, simply remove one-half the thickness of the stock to a length comparable to the width of the stock on both ends of all pieces.
6.Half-inch holes to accommodate
the rod will have to be drilled in the exact centre of the top horizontal
pieces before assembling the top portion of the support frame. Slip
the 1/2" steel rod with barrel attached, through these holes and insert
the cross members into the dadoed uprights. Fasten with 1 1/2" #10
screws. Next cut the 1 x 3 x 23 1/4" piece at 45-degree angles at
both ends, and attach with 1 1/2" #10 screws across corners as shown
in the illustration.
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7. For extra support, use 2 x 4 x 27" cross boards an each side. Cut them to an angle as the upper end is at 14 1/2" and the lower end 29" from the top of the 2 x 4 frame horizontals.
8. Drill several rows of
1/4" holes along the bottom of the barrel exactly underneath the door
opening to eliminate excess moisture. Paint the outside of the unit
a flat black colour.
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