Siderelief angle

Relief cuts near barrel staves. To give the barrel staves the appearance of being wrapped around the wooden barrel, use a 1/4” parting tool to make relief cuts in the wood directly adjacent to the copper. Allow the copper to protrude 3/32” above the wood, then use the parting tool to gently round over the edges of the copper to soften the feel.

Cut four matching copper pieces. Using your bandsaw with a 3/8” or wider blade, cut pieces of 1/8” thick copper plate to the same dimensions as your wood pieces, 1.75” square.

Temporarily attach an extension. Using hot glue, temporarily attach the piece that the wood pieces were cut from originally. I initially tried turning by simply placing the blank onto a mandrel, but the copper introduced more resistance than a standard wood or resin blank, and the force proved too much for the glue bond and it tore the insert from the blank.

Relief anglechart

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Sand and finish. Wet sand through 400 or 600 grit to polish the copper, then apply a few coats of your favorite spindle turning finish. I use Mylands Friction Polish for projects like this because it delivers a nice glow and builds up quickly.

Turning bottle stoppers is highly addictive, and this copper and wood barrel wine bottle stopper is an example of where that rabbit hole can take you. Did you know that you can turn non-ferrous metals such as copper on a wood lathe? Yes, indeed, and that’s one of the keys to creating this unique project. Check out my previous blog post for some basic tips for turning bottle stoppers, and here I’ll focus on the specifics for turning this copper and wood barrel.

Endrelief angle

Install a threaded insert. Follow the steps in my previous blog for additional details on this. Drill a 5/16” hole using a Jacobs Chuck, apply some polyurethane glue, then press a 3/8” threaded insert into the hole using the live center on your lathe.

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Abrade the copper surface. Using 80 grit sandpaper, scuff the surface of the copper pieces on each side to produce a better bonding surface for the glue.

Glue and clamp. Dampen all surfaces and apply polyurethane glue, then clamp until the glue cures. Polyurethane glue works better than traditional PVA based wood glue for this project because polyurethane provides a better bond on a non-porous surface such as metal, whereas PVA glues requires penetration into the wood pores to form a bond.

Relief angletool

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Install a barrel bung. Drill a 1/8” hole and tap in a short section of 1/8” diameter copper rod to give the appearance of a bung plug. Secure the copper with a couple drops of CA glue.

Relief angledrill bit

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Restoration projects, in many cases, include the rehabilitation of deteriorating relieving angles by welding additional reinforcement or providing new coatings to the existing angles. The structural connections of relieving angles, to the overall structural frame, is an important aspect of the structural strength of the system. In addition, the proper leveling of the angles, as well as the type of attachment, is important to the integrity of the systems they support. The accuracy of the jointing and the integrity of the masonry systems being supported by the relieving angle are totally dependent upon these supports.

Relief anglemasonry

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Rakeangle

The proper scheduling of relieving angles is essential to the progression of work on the project. In many cases, the relieving angles are either galvanized or stainless steel, requiring a long period of time, from approval of shop drawings to delivery to the jobsite. Relieving angle size and location is determined by the structural engineer for the project. Incorrect design can cause failure of the system being supported by the relieving angles.

Definition of Relieving angle in Construction A structural steel member that relieves the weight of another system constructed within the building.

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Cut some wood pieces.   Start with a piece of wood that is 1.75” square by 8+” long, and make clear marks on two sides to help you keep track of the orientation when you assemble your blank. Make 5 cuts across the grain; the middle piece cut to 1/2” thick and all the rest cut to 1/4” thick. This is best done on a table saw using a stop block to ensure that your cuts do not get trapped between the blade and fence. Mark each piece on the top as you cut it, to ensure that you can assemble in the same sequence for grain consistency.

LIGHT RADIAL: DEPTHS OF CUT, THE HIGHER OF THE RECOMMENDED SURFACE SPEEDS (SFM) SHOULD BE USED ... CONVENTIAL MILLING SHOULD BE USED AND FEED PER TOOTH SHOULD BE ...

Relieving angles normally relate to masonry brick, stone, or other types of cladding that have significant weight to their systems. This weight is held up by a relieving angle that is supported on both ends by a structural member, or supported along its length .

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Relief anglefor brick

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Turn to a barrel shape. Turning copper is a slow process, and worked best when I concentrated more of my efforts on the copper rung areas rather than spending even time on the wood and copper portions. I experimented with different turning tools and found that the standard insert from Easy Wood Tools worked best in removing copper at an acceptable rate, and leaving a smooth surface finish.

Install stopper hardware. Install your choice of bottle stopper hardware into the threaded insert. Here, I’m using a solid stainless steel stopper from Niles Bottle Stoppers.

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