Making a Wooden Vaulting Barrel

16 - 1 x 3" boards glued and nailed on

1 x 3 boards laminated to make the legs

16 boards were used plus 2 for each leg

1 x 3 boards, 5' long nailed and glued into place onto 4 pieces of plywood cut identically

shape could be rounder, not as wide this is 2' x 2'

4  1" plywood pices:  2 ends, 2 in the middle

glued 1 x4 boards for the legs Handle is coming off as it is not needed for moving the barrel

Making a Wooden Vaulting Barrel

Materials

1- 1' or ¾ " plywood  
16 - 1x3" boards
2 - 2x4' boards (unless using left over 1 x 3 boards)
wood glue
12 carriage bolts (⅜" by 3 ½ ") to attach the legs
nails:  2" common

Tools

hammer

saw
wrench or ratchet

Procedure

1.  Cut 1x3 boards to 60"  (be accurate so you don't have to trim)

2.  Have a skilled woodworker cut the plywood into an arch shape.  must be identical,  Cut 4 arches:  20" diameter by 20-24" tall (2 ends and 2 middle supports) (sides rounder than the one in photo)
2' wide is a bit too wide for comfort

3.  Glue and nail the 1x3 boards onto the plywood.  A gap can be left, which will happen on the curves.

4.  Cut 2x4 into 4' lengths (or shorter if you want a short vaulting barrel)

5.  Attach legs to each end of the barrel on the inside:  angled for stability
     • At least 6" attached to the end of the barrel
     • Drill holes for the bolts (plywood end and 2x4).
     • Nuts go to the inside.  3:  staggered up the board.

Cover

• 1" or ¾" foam (seat foam is very dense and durable) 60" long.  Duct tape can be used to join the foam to make wider.  Duct tape did not come off easy.  I attached narrower pieces on the lower sides so that the joins were not in a high stress area.
• Cover foam with fabric:  outdoor furniture fabric, boat cover, thick vinyl..feels nice, has a tight weave
  • Tack around the edge of the barrel to hold into place
  • from the centre on both sides out to the ends, alternating the sides tacked.  1 tack on each side of the ones already in place
  • must be pulled tight as you can, no wrinkles
• velcro with stick on one side was attached to the foam and barrel on the ends, middle so the fabric could be pulled tight.  Worked very well.
• Fabric (dense, outdoor fabric that had a nice feel) was stretched over the barrel and tacked into place with fabric tacks
• The barrel end could be covered so it looks nicer

or sew a seam around the end edges, thread a cord through and pull tight.  Add webbing straps at the sides to pull tight under the barrel

• Cover wood with carpetingc• velcro with stick on one side was attached to the foam and barrel on the ends, middle so the fabric could be pulled tight.  Worked very well.
• Fabric (dense, outdoor fabric that had a nice feel) was stretched over the barrel and tacked into place with fabric tacks
• The barrel end could be covered so it looks nicer

Handles

• Buy vaulting barrel handles from Skyline Vaulting in Langley, BC   (easiest)
• Attach with tie down straps, attach to barrel to stop twisting. (grommet and screw)

Notes

• 1x3 boards that are unplaned would be better than planed boards. (thicker)
• Carrying the barrel at the bottom edge of the barrel is easier than attaching handles
• Wheels on one end make it easier to move by one person

Not tippy, seems to be sturdy enough when 11 year old boys are jumping on it and with multiple kids