This project was built and designed by Alex and Emily Tarsha from Tarsha Homestead. It’s a functional and stylish barn door made for their shop bathroom, blending reclaimed wood and galvanized metal to create a rustic, industrial look.
With an emphasis on using leftover materials and thoughtful design, this build offers a practical way to add personality and privacy to a space. It’s also a great example of how simple joinery and a bit of creativity can result in a standout feature piece.
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Prepping the Wood and Embracing Imperfections
The first step in the project involves milling the lumber down to clean it up. Using a planer, Alex and Emily remove surface inconsistencies and bring each board to a uniform thickness.
Rather than aiming for perfection, they embrace natural imperfections like cracks and knots. These characteristics add charm and enhance the rustic look of the door. Their approach celebrates the texture and authenticity of the material, without over-sanitizing it.
Trimming Out the Door Frame
Before building the door, the rough opening is trimmed to fit the frame. Careful measurements and clean cuts help make sure everything lines up, which is important for both looks and functionality.
A multi-tool is used to make precise adjustments where needed, especially around baseboards and thresholds. This step helps ensure the door fits properly and avoids any gaps when installed.
Constructing the Door Frame
With the frame area prepped, the door itself begins to take shape. The outer frame is built first using wood glue and screws for strong, lasting joints.
During this process, they keep an eye on excess glue to prevent it from drying in visible spots. Any leftover glue can cause blotching when stain is applied later, so early cleanup is key to achieving a smooth finish.
Adding Galvanized Metal for Contrast
One of the unique features of this barn door is the use of galvanized sheet metal as a design accent. The metal is cut to size and placed between wood frame sections, adding texture and reinforcing the industrial look.
Safety precautions are taken while working with metal, especially during cutting. Sparks and sharp edges are managed carefully to prevent accidents, with tools chosen to maintain clean edges without excessive heat or warping.
Applying Stain and Sealing the Wood
Once assembled, the door is sanded and stained. A carbon gray stain is chosen to deepen the tones of the wood while still letting the grain show through.
The color works well with both the rustic elements and the galvanized metal. It also adds protection for the wood while maintaining a worn-in, vintage appearance that matches the overall style of the homestead shop.
Installing the Sliding Hardware
The next step involves installing the barn door hardware, which was sourced locally. Supporting local vendors not only ensures the right aesthetic match but also strengthens community relationships.
Alex and Emily follow the manufacturer’s instructions carefully to align the hardware and mount the door securely. Proper installation helps the door slide smoothly and sit flush against the frame when closed.
Creating a Custom Pipe Handle
Instead of buying a pre-made handle, they make their own using black iron pipe fittings. The combination of elbows, nipples, and flanges creates a sturdy and eye-catching handle.
Spray-painted in a matte finish, the pipe handle complements the rest of the door’s industrial touches. It also adds another layer of DIY personality to the project, showing how small details can elevate the overall design.
Bringing It All Together
With the hardware and handle installed, the door is ready to use. It slides effortlessly and adds instant character to the bathroom it was built for.
The pairing of wood and metal, clean lines, and thoughtful material choices makes the finished piece both functional and visually compelling. It also offers inspiration for anyone looking to use reclaimed materials in a smart and stylish way.
A Project That Combines Style and Utility
This rustic barn door is a practical build that showcases personality through its materials and details. By reusing what they already had and combining it with a few new elements, Alex and Emily created something that feels both handcrafted and cohesive.
The door is more than just a privacy solution—it’s a visual feature that adds to the story of their homestead shop. It’s a reminder that woodworking projects don’t have to be complex to be meaningful.
Please support Alex and Emily by visiting their website: https://tarshahomestead.com/.