The nice thing with these boards is you only have to make horizontal cuts and your vertical lines are formed by the staves for a nice clean look.
If you want to have a door versus just an opening on your wine barrel outdoor sink, save the wood staves.
Once the two cuts for the door opening of your wine barrel outdoor sink are made, be sure to mark the boards so you know the order that they should be reassembled.
While making this one I discovered that these wood staves don’t necessarily want to go back to the same shape that they were when connected to the wine barrel outdoor sink. I used metal strips found in the hardware/roofing section at the hardware store. There are a variety of sizes available. For me, I had to trim off a couple of inches with a hack saw to fit this door.
The wood will want to curve so slightly bend the metal strips and connect them for your wine barrel outdoor sink, checking the opening as you go to get the correct curvature of the door to the barrel. As you can see from mine, it took some shims to get a closer match.
An alternate method would be to connect the metal strips through the top once you cut the opening for the sink and connect the metal strips while the barrel is still intact. (A method I would do if I make another one.)
After finding the center of the wine barrel outdoor sink, I placed the copper sink upside down on the top of the barrel and traced the outer flange. I then measured in 7/8″ to allow a lip to secure the sink.
I made a pilot hole on the inside portion of the wine barrel outdoor sink to get the jigsaw blade into to cut out the sink. You may have to make a few pilot holes if you are not able to turn the jigsaw at the corners of the sink opening.
I used a hole saw to make the opening for the wine barrel outdoor sink’ faucet. With the single-lever style, I cut a 1 1/4″ hole for the faucet.
A few boards towards the front of the sink were not glued well, so I secured them together with a couple of nail/staples as shown.
The barrel tops are usually glued well but this barrel was not as secure as I would have liked.
This portion is up to you on how you want the outside finished of your wine barrel outdoor sink. You could go au natural and let it weather over time or treat it to protect the oak and metal, I chose to protect.
I first sanded the metal rings with a #000 steel wool to remove any rust or film. I taped above and below each metal ring with painters blue masking tape, applied a metal primer and four coats of the black satin paint to the rings.
I used metal primer and a latex-based Rust-oleum satin black paint for the rings.
Make sure that you choose a paint that does not react with galvanized metal as some oil-based paints can.
I used a deck stain/water repellent on the outside of the wine barrel outdoor sink with no pre-sanding to allow better absorption of the stain.
Allow drying overnight before attaching the sink and faucet.
For the sink, I drilled in eight locations to help secure the sink to the wood with the copper roofing nails. I then drilled a pilot hole slightly smaller than the copper nail into the oak through the newly created hole in the sink to prevent the oak from splitting but have some bite into the wood.
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