Whynot,
I've been successful at fully hydrating a barrel in 2-3 hrs, it has worked on the last two barrels that I've received, my last one just a few days ago. I use a plastic storage container, Rubbermaid type that is big enough to fit the barrel inside and the walls need to be 6 inches high or more, I have several pots of water boiling and ready to go, I'll start to prep the barrel as per their instructions, I start by adding boiling water and placing the barrel on its head, I add boiling water on the head that is in the air, and then add several pots of boiling water to the plastic storage container that the barrel is in.
I continue to keep the pots filled with water and boiling, and I continue to add more water to the barrel and rotate it so the other head is exposed and add water to that.
After this i lay the barrel flat and add more boiling water to it, and to the storage container. I'll literally start to baste the barrel with the hot water in the storage container in an attempt to hydrate the staves, I'll slowly rotate the barrel, trying to get the entire inside and outside of the barrel in contact with the boiling water.
After 2 hrs or so, I make sure that I fill the barrel with boiling water and put a solid bung in it and put it on the stand.
I usually don't see any leaking.
The barrel actually kept the water hot (the barrel was warm to the touch) for over 15 hrs.
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