This project is by DIY Pete. This DIY project is not only budget-friendly but also allows you to add a personal touch to your home decor.
In this tutorial, we will guide you step by step on how to build your own custom sliding barn door. From measuring the door opening to creating the hardware, this project is perfect for any woodworking enthusiast.
Step 1: Measure the Door Opening
The first step is to measure the door opening. Typically, it’s recommended to build the barn doors about four inches wider and two inches taller than the opening. This ensures that the door overlaps each side by a couple of inches. This overlap is crucial for both aesthetics and functionality.
Step 2: Prepare the Plywood
Next, grab a sheet of plywood and transfer your measurements onto it. Since we’ll be wrapping the door with 3/16 of an inch steel, subtract about 3/8 of an inch off the width and height of the plywood to account for it. Once you have marked the plywood, use a circular saw to make the cuts. A straight edge can be helpful for this, but if you can follow the line closely by eye, that will work just fine.
Step 3: Cut the Pickets
Now it’s time to start making cuts. Cut 32 pickets down to 37.5 inches. Make sure to allow the pickets plenty of time to dry out before working with them to minimize shrinking and gaps between the boards. To make the cutting process more efficient, consider setting up a stop jig on your table saw.
Step 4: Attach the Pickets
Once you have cut the pickets, lay them out and organize them as desired. Next, attach the pickets using a combination of construction adhesive and brad nails. Line up the pickets so they’re flush with the edges of the plywood, and work from one end to the other to secure each picket. After completing one side, flip the door and repeat the process.
Step 5: Sand the Door
As fence pickets are usually rough, you will want to sand them down to smooth over the boards. Use 120 grit sandpaper for this task. You can sand them completely smooth, but if you prefer some texture, don’t sand them down all the way. After sanding, add a few more nails as needed and sand the door edges to clean things up.
Step 6: Apply a Finish
Apply a finish of your choice. For this project, the aim is to seal the boards while keeping the cedar looking as raw and natural as possible. A clear satin water-based sealer works well. Initially, it will darken the wood, but as it dries, it will lighten up, providing a natural look. Allow the first side to dry, then flip the door and seal the back side.
Step 7: Prepare the Metal Flat Bar
Next, lay out the 3/16 of an inch by 2-inch wide metal flat bar and determine the lengths to cut it. You will need four pieces in total. The long vertical pieces will overlap the edges of the smaller top and bottom pieces. Use a cut-off saw or a reciprocating saw for this task.
Step 8: Clean Up the Edges
Once all pieces are cut, use an angle grinder with a flap disc or a bench grinder to clean up the edges. Measure and mark for holes that will be drilled to attach the metal to the wood later. For this, I used three screws on the top and bottom and six screws on each vertical side.
Step 9: Drill Holes for Attachment
A drill press will make it easier to drill through the metal, but a normal drill and metal bit will work too, though it may be more tedious. Keep the drill bit cool by spraying it with WD-40 occasionally. Once the holes are drilled, seal the metal with a clear matte spray sealer and spray paint the screws with a dark metallic paint to match the steel.
Step 10: Attach the Metal to the Wood
Add construction adhesive to the steel before attaching it with screws. Line it up, then pre-drill holes at each screw location. Secure the metal to the wood with one-and-a-half-inch screws. Move on to the next side and determine the placement for the holes, ensuring they are spaced evenly.
Step 11: Make the Door Hardware
Now it’s time to make the door hardware. After researching affordable wheels and hardware, I decided to follow April Wilkerson’s advice from wilkerdews.com. You can check her tutorial for barn door ideas, as she offers a great selection of DIY projects. For the hardware, I cut two pieces to 16 inches in length and drilled two mounting holes to attach the door, along with a larger hole for the wheel.
Step 12: Install the Hardware
When drilling the holes, start with a smaller bit and progress to the final size using a couple of different bit sizes. This will help in getting precise hole placement through the quarter-inch thick metal. Spray paint the bolts, washers, and nuts before positioning the metal on the door.
Step 13: Hang the Door
Now it’s time to carry the door inside and put it in place. It’s advisable to have a friend or family member help with this step, as the door will be heavy. Use a scrap board that is half an inch thick to simulate the height you want to hang the door. Locate the studs in the wall, usually about 16 inches on center, and mark their locations as well as the level where the rail should be placed.
Step 14: Create the Rail
Next, you will want to make the rail. Cut the two-inch by quarter-inch thick metal slightly shorter than the spacer board you made earlier. Transfer the marks to the metal and ensure they align with the stud locations. Measure down an inch and a quarter for where the leg bolts will go, ensuring they are slightly under center.
Step 15: Install the Rail
Drill a hole through the wood for the leg bolt to match up with the holes in the metal. Create additional spacers to ensure there’s room between the door and the wall. Paint the dowel spacers and the board spacer to match your wall. Attach the board spacer to the wall with wood screws at each stud, then drill a pilot hole for each leg bolt location.
Step 16: Final Adjustments
After putting up the rail, use dowel spacers and then the rail followed by a washer and leg bolt for each hole location. Double-check that you are going into a stud each time for a secure installation. If all goes well, the rail should be rock solid and able to hold a lot of weight.
Step 17: Add a Handle
Add a handle to the front side of the door. I chose a bar pull handle to complement the Scandinavian style theme I’m aiming for in my home office. For mounting the handle, I had to get two-and-a-half-inch long bolts to go through the two-inch thick door.
Step 18: Create Door Stops
Next, create stops for the door using angle iron. Cut two pieces, clean them up with a grinder, and drill a hole in each on the drill press. Decide where each stop should be on the rail and drill a hole in the rail for attachment. Use an inch-long bolt for each and add a felt pad or rubber piece to each stopper.
Step 19: Install the Track
Finally, create a channel or track to keep the door in place. I made mine out of leftover angle iron, drilling a few holes to secure it to the floor. The track needs to be longer than usual, as I needed to slide the door far enough to clear the light switches. Use screws to secure the track to the floor.
Conclusion
Congratulations! You’ve successfully built and installed your sliding barn door. This project not only enhances your home decor but also provides functionality. Thanks for following along, and best of luck with your upcoming projects!