Greg Bickal's DIY Series: Making a 55 gallon barrel Square
Many people use 55 gallon barrels for pond projects. The barrels are very durable and relatively in-expensive (usually under $10). The round shape does make it difficult to install bulkhead fittings. It is also difficult to make skimmers. That is why I came up with the idea to use heat to re-form the barrel into a square shape.


Materials

Description	Qty	Size	Price
Barrel	1	55 gallon	$10
Wood	2	2x4x8	$2
Charcoal Briquettes	1 10lb bag	This is a common item and holds a good clean fire without much flame. You could build your fire for free with scrap peices of wood.	$4
Steel Bucket	1	5 gallon	Scrap
Car Jack	1	You should have one of these in the trunk of your car!!	Free

1. Drill a pilot hole in the side of the barrel at the top. The hold should be big enough to accommodate your Jigsaw/Sawsall blade.
   
2. Cut off the top of the Barrel with a Jigsaw or Sawsall.
   
3. Measure the diameter of the barrel. Most 55 gallon barrels should be 72" in diameter. Divide this number by four, 72/4 = 18". This will be the width to make your wooden forms.
4. Cut one of the 2x4's into 24" lengths. You should have 4 peices.
5. Cut the other 2x4's into four 15" lengths, and two 18" lengths.
6. Nail two frames together as shown. It should be 24" long.
   
7. And 18" wide.
   
8. Use a rough file to smooth out the edges.
   
9. Pour the Briquettes in the bucket and light on fire. To gain extra heat, I added a small squirrel cage fan to blow oxygen directly to the bottom of the Briquettes through an aluminum tube. Do not try this unless you are very experienced with fire.
   
10. After the Briquettes are burning well, place 3 bricks around the perimeter. This keep an airspace open to keep oxygen to the Briquettes.
    
11. Place the barrel upside-down over the bucket. Be sure to center the barrel over the bucket.
    
12. Monitor the barrel carefully. Rotate occasionally to avoid hot spots.
13. When the barrel is very soft and plyable (you can easily bend it), take it off the Briquettes and turn it upright.
14. Insert the forms and car jack into the barrel as shown.
    
15. Tighten the car jack until the barrel is formed into a square. If the barrel does not form very well, it might need more time to heat up.
    
16. Leave the form inside the barrel and allow the barrel to cool over night. If you are re-forming multiple barrels, you can spray cold water on the barrel to shorten the cooling process. Make sure the barrel is very cool, otherwise it will warp out of shape.
17. The finished product. If you plan on burying the barrel in the dirt, I would recommend building a wood ring that would fit inside the top of the barrel for extra support.