Wondering how to make a whiskey barrel? We think it’s a process youβll love reading about. Today, weβll dive into the steps companies take to construct their bourbon barrels and the like. The barrel is a huge factor. We donβt want it going unnoticed. So, here we go!
Cooperage
What is cooperage? Itβs the crafting of barrels. Itβs maybe the most overlooked piece of the whiskey process. But you guys. The barrel. The barrel is in many ways responsible for the flavor we all know and love.
Some of you may never have thought about this largely human-crafted component. Weβre saying, think about it! Itβs cool. Even with all the technological advancement, these barrels require human skill. They require a passion for whiskey and some serious craftsmanship.
We all should send up a big salute and thank-you to the coopers of the world right now. Do it. Thank them. You wouldnβt be loving whiskey if it werenβt for these folks.
How to Make a Whiskey Barrel
Join us for a quick look at how whiskey barrels are crafted for your whiskey-loving soul. The liquor wouldnβt be what it is without barrels. This is where some definite magic happens.
STEP 1: Start with American White Oak

This specific wood is the first step. Itβs the source of all the complex, creamy flavor. With this particular oak, youβre eventually tasting vanilla and even coconut. And itβs also known to be quite leak-resistant.
STEP 2: Create and Prep the Staves

The wood is then divided into long, slender barrel-body pieces. These are called staves. If youβve ever installed your own wood flooring, you know that wood can change shape if you arenβt careful. Itβs best to let it dry. Same goes for these staves. Warping and/or contracting isnβt what you want.
Itβs common for the whiskey barrel staves to go into a kiln. Then they dry for around two months. Moisture is the enemy and canβt be allowed to move through the joints of the barrel during the whiskey process. All these staves have to fit perfectly together–for the sake of the whiskey!
Check out this short video from 1992: Making Whiskey Barrels by Hand!
STEP 3: Add Tops and Bottoms

The circular tops and bottoms are attached to the staves before the signature iron hoops (belts around those perfectly round bellies).
STEP 4: Shape the Barrel

After the hoops are in place, the staves are bent. This is often accomplished with steaming. This softens the staves and creates the curvature of the barrelβs body. And itβs almost like a wheel,
STEP 5: Char the Barrel

Barrels travel down a conveyor belt where a gas-powered flaming system gives the inside of the barrel its char. The flavor profile of your whiskey gets amped up right here, before anything even resides in the barrel.
As the whiskey matures, itβll take on a unique taste, thanks to the char. All that flavor of the charred barrelβand the white oak tree itself–will seep into your whiskey. Amazing!
See a bit of the charring process here. Wood, fire, water. Yes!
Hug a Barrel Next Time You See One
Barrel hugs are a thing, right? If theyβre not, they certainly should be. Donβt be shy. Get in there. Wrap your arms around that belly of awesomeness.
The next time youβre having your favorite pour, remember how whiskey barrels are made. Consider all the love, skill, talent, patience, and nature that really does go into making the libation in your glass what it is.
Ever been involved in the process of how to make a whiskey barrel? Or seen it done? Share with us below. And donβt forget to check out our online store. We believe in skill and craftsmanship just like a cooper does. Our handcrafted, unique whiskey decanters make a statement. They also make great gifts for the whiskey lover in your life. (Or treat yoβself.)
And donβt miss our whiskey barrel shaped glasses. This way, youβll always remember whatβs behind the booze. Raise your barrel glass to the barrel magic!
Well, this has been more fun than a barrel of monkeysβ¦er, whiskey. Until we meet again, whiskey kids!