This project was built and designed by Pete from DIY Pete. It’s a creative way to add character and function to your home using simple materials and tools.
Sliding barn doors are a smart solution when you want to save space or create a bold design feature. Pete’s version is made with plywood, cedar pickets, and steel accents for a custom, high-end look.
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Starting with Measurements and Planning
Before cutting any materials, Pete begins by measuring the door opening. The barn door should be about four inches wider and two inches taller than the frame to fully cover the space.
After calculating the dimensions, a sheet of plywood is marked to reflect those measurements. To account for the steel wrap that will frame the outside, about three-eighths of an inch is subtracted from both the width and height.
Cutting and Preparing the Wood
Using a circular saw, Pete cuts the plywood along the marked lines. A straight edge can help keep things accurate, though a steady hand works just as well.
The face of the door is covered with trimmed cedar pickets. Around 32 boards are cut to a consistent height and arranged in the order they’ll be attached.
Setting up a stop jig on the table saw makes repeat cuts faster and more accurate. Allowing the boards to dry before use helps minimize shrinking or gaps after installation.
Assembling the Door
Construction adhesive and brad nails are used to attach the pickets to the plywood. Pete starts at one end and works across, making sure each board sits flush against the edge.
After completing one side, the door is flipped and the process is repeated. A light sanding with 120-grit paper smooths the surface while leaving some texture for a rustic feel.
Finishing the Wood
A clear satin water-based sealer is applied to both sides of the door. This finish protects the wood while letting the natural grain and color of the cedar show through.
The first side is sealed and allowed to dry before flipping and sealing the back. Two coats ensure an even finish and extra durability.
Adding the Metal Trim
To frame the edges, Pete cuts four pieces of flat steel bar. Each piece is trimmed to match the side it will cover, then cleaned up with an angle grinder for a smooth look.
Mounting holes are marked and drilled through the steel. A drill press is helpful here, but a handheld drill works fine with a little care and a dab of lubricant to keep the bit cool.
After drilling, construction adhesive is applied to the steel before it’s attached to the wood with screws. This extra step adds holding power and prevents movement over time.
Creating the Sliding Hardware
For the wheels and brackets, Pete draws inspiration from a design by April Wilkerson. Steel pieces are cut, shaped, and drilled to create functional and durable mounts.
Various washers and bolts are used to create smooth rotation. Proper alignment ensures the hardware functions well and adds to the door’s visual appeal.
Mounting the Door
Due to the door’s weight, Pete recommends getting help for the installation. A scrap board can be used as a temporary spacer to simulate the desired height.
Stud locations are marked on the wall, and the sliding track is installed securely into the framing. Leveling the track is key to smooth movement once the door is hung.
Final Adjustments and Details
With the track in place, the door is lifted onto the rail and tested for smooth sliding. Minor tweaks can be made if anything feels off.
A handle is added to the front for everyday use. On the back, Pete installs a recessed pole that acts as a clean and functional pull.
Why This Project Works
This sliding barn door is a great example of combining practical woodworking with custom design. It provides a functional room divider while also becoming a focal point in your space.
Building a piece like this is a rewarding experience for any DIYer. It offers a chance to work with different materials, tools, and joinery while creating something beautiful and useful.
Want to See the Full Build?
Please support Pete by checking out all his plans here: https://www.diypete.com/diy-project-plans/