Are you a sauna enthusiast looking to add a touch of elegance to your outdoor space?

Building a DIY barrel sauna might be the perfect project for you. 

With a blend of traditional Finnish sauna bathing and a modern, nature-inspired aesthetic, a DIY barrel sauna is not only a functional addition but also a statement piece for your home. 

This comprehensive guide will walk you through the process of creating your own barrel sauna from scratch. 

So get ready to embark on a rewarding journey as we guide you through each step of the construction process.

Understanding Barrel Saunas 

Before diving into the building process, let's explore what makes a barrel sauna unique.

A barrel sauna takes its name from its distinct shape, resembling a life-sized wine barrel tilted at a 90-degree angle. 

Constructed using wood planks with notched edges and secured by stainless steel straps, the barrel sauna offers durability and a charming aesthetic. 

Also, depending on your preference, you can choose between a naturally lit sauna with glass windows and ceilings or a classic all-wood design.

How Does a Barrel Sauna Work? 

While the shape of a barrel sauna might seem different, the fundamental principles of heating and operation remain similar to other saunas. 

A barrel sauna utilizes sauna heaters, just like traditional saunas, to generate heat. Electric sauna heaters, wood-burning heaters, or gas heaters can all be suitable options for your barrel sauna. It's essential to prepare the sauna space by running electrical wiring, water lines, and properly insulating the enclosure to ensure a comfortable sauna experience.

Key Considerations Before Starting Your DIY Barrel Sauna Project 

To ensure a successful build, there are crucial factors you should consider before starting your DIY barrel sauna project:

1. Location

Selecting the ideal location is vital. 

Backyards are often preferred due to the ample space they offer and the ability to create a tranquil and private sauna experience. 

Garages can also serve as suitable locations, providing pre-existing electrical wiring and protection from outdoor elements. 

For those seeking a traditional touch, building the sauna by a pool can replicate the Finnish tradition of taking a sauna bath followed by a plunge into cold water.

2. Size

Determine the size of your barrel sauna based on the available space and the number of bathers you anticipate. Consider factors such as the depth, width, and height of the sauna enclosure. 

Electric sauna heaters require less space compared to wood-burning or gas heaters, which may influence the size of the sauna.

3. Sauna Wood

Selecting the right type of wood is crucial for durability, insulation, and bather comfort.

Opt for high-quality wood that can withstand extreme heat and humidity without knotting. Popular options include Douglas fir, Nordic spruce, Hemlock, Pine, and Common aspen.

4. Sauna Heater

Choose a sauna heater that meets your specific needs and preferences. 

Electric steam sauna heaters are compact and energy-efficient, while wood-burning heaters provide an authentic Nordic sauna ambiance. You may also consider installing infrared sauna heaters for an infrared barrel sauna experience.

The DIY Barrel Sauna Building Process

Now that you've considered the essential aspects, it's time to start building your DIY barrel sauna. Follow these step-by-step instructions:

Step 1: Preparing the Staves 

To create a snug fit and achieve the barrel shape, prepare the staves using a bead and cove joint. 

Use a router table and cove router bits to shape the wooden boards, ensuring proper alignment and a secure fit. Pay attention to the top and bottom staves, which should have two convex edges to prevent water leakage.

Step 2: Prepping the Dado Joint 

Make dado cuts in the staves to create dado joints where the front and back end caps will fit. 

You can use a table router with a straight flute router bit to achieve this. Ensure precise alignment and a tight fit.

Step 3: Building the Front and Back End Caps 

Create tongue and groove joints on the boards to form dual squares for the front and back end caps. 

Make circular cuts on the boards, and consider rough cutting some for the narrower top and bottom sections of the sauna.

Step 4: Building the Sauna Door 

Building a sauna door is relatively straightforward. Cut out one of the straight sides of the barrel to the desired door measurement and frame it back using door clamps.

Consider adding windows to the door for enhanced aesthetics.

Step 5: Preparing the Location 

Choose a flat and solid surface for the sauna installation, ensuring stability. 

Whether it's a concrete surface, a gravel base, or a sturdy deck, proper preparation of the location is crucial.

Step 6: Assembly 

This step involves assembling the sauna using the prepared staves and end caps.

  • Setting the Cradles and Staves in Place

Align the cradles and secure them by screwing in the staves until they fully cover the cradles. Ensure that the dado joints align perfectly, and the structure is sturdy.

  • Putting up the Sauna Walls

With the cradles and staves in place, begin assembling the walls of the sauna. Enlist the help of another person to assist with fitting the end discs into the dado cuts on the staves.

  • Inserting the Staves

 Continue inserting the remaining staves until the walls are complete. Pay close attention to the alignment of the dado joints.

  • Tightening the Wire Rope

Once the sauna structure is assembled, use wire ropes and rope clamps to tighten and secure the entire barrel structure.

Step 7: Installing Sauna Benches 

Choose between ready-to-install benches or custom-building your own benches to suit your preferences. Install them securely inside the sauna enclosure, ensuring comfort and functionality.

Step 8: Placing the Sauna Heater 

Install the sauna heater according to the manufacturer's instructions. Whether it's an electric heater or a wood-burning heater, ensure proper wiring and safe placement within the sauna. Consider ventilation and chimney placement for wood-burning heaters.

The Worth of DIY Barrel Sauna Kits 

If you prefer a more convenient option, DIY barrel sauna kits are worth considering. These kits include all the necessary components for assembly, saving you time and effort. 

However, building a sauna from scratch can be a fulfilling experience for those with the time and patience.

Conclusion

Embarking on a DIY barrel sauna project is a rewarding endeavor that allows you to create a unique and personal sauna experience. 

With proper planning, attention to detail, and the right materials, you can build a stunning barrel sauna in your outdoor space. 

Remember to prioritize safety, follow manufacturer instructions, and seek professional assistance when needed. 

Enjoy the satisfaction of having your own homemade barrel sauna and the countless relaxation and wellness benefits it will bring.