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Build a Sliding Barn in 60 minutes!
Have you ever wanted a sliding Barn door to cover up that ugly space in your house, or to replace those outdated french doors with something rustic and majestic? Barn doors are the easiest, cheapest, quickest things to put in your house that also serve as a focal point that others will admire. Everyone who comes into my house loves my barn doors and often ask me to make them some for their home. But I am all about sharing my knowledge with the world about how to make these beautiful barn doors yourself! Projects are fun to do and you will feel a sense of satisfaction when you complete it on your own. Most people do not DIY because of time, but I am here to show you how you can build a beautiful barn door in 60 minutes and with limited tools.
Do not be afraid of this project, you can do it and do it well!
**See below a complete list of tools needs and other materials used to build the barn door. I have also included a step by step guide below so that you can build one just like this if you want!
Barn door dimensions- 8 feet tall, 4 feet wide (38.5 inches wide to be exact)
Weight- 80lbs
Price- $140.00
Time to build and hang the door- 3 to 4 hours total work time
Materials:
8 (1x6) boards at 8 feet long ($5.57 each Home Depot)
1 (1x6) board at 10 feet long ($6.88 Home Depot)
3 (1x4) board 6 feet long ($3.88 Home Depot)
1 Barn Door handle ($4.98 Home Depot)
1 6ft. Sliding Barn Door hardware (Amazon $43.00)
White paint (1 gallon is $10.00 at Walmart: I used leftover white primer from a previous project so any kind of paint will work and it will only take about a quart of paint depending on how may coats you use)
Sand paper ($3.82 Walmart for 5 sheets)
Wood Glue ($4.68 Lowes, this seems unimportant since we will be using screws but it keeps the door from bowing)
1 1/4 inch Screws ($9.37 Lowes, I just used exterior screws, but any screw will work as long as it is 1 1/4 inch)
Wood Filler (Optional)($7.97 Lowes)
Tools needed:
Drill with drill bits
Jig Saw ($24.98 Lowes) (or any saw you have)
Level ($6.98 Lowes)
Socket Set
Measuring tape
pencil
Step by Step Guide to building a Barn Door in 60 Minutes
Step 1: Lay 7 (1x6x8) boards flat on the ground and slide them together side by side. Make sure the bottom of the boards are even and no board is sticking out longer or shorter than the other. This will form the shape of your door. (Most boards are not perfect so just make sure it is as close as possible.)
Step 2: Lay 1 (1x6x10) board over the top running perpendicular to the other boards to create the top border of the door. Use a pencil to draw a line where you plan to cut the excess board that sticks out. Use a measuring tape as needed with a straight edge. Cut the board using the saw as straight as possible. This board will be used again to make the bottom of the door frame. Repeat this step with the bottom of the door.
*Make sure the boards are pushed together as tight as possible so there are no gaps when you screw the top and bottom boards on.
Step 3: Once the boards are cut, use the Wood glue to glue the top and bottom boards on the door. Squeeze the wood glue in a squiggle pattern on the top board and place firmly on the door. Repeat with the bottom board.
Step 4: Once the top and bottom boards are glued, measure the length between the top and bottom boards and cut 2 of the remaining (1x8) boards according to those measurements. (It should be approximately 6 feet. These boards will go on the sides of the door and serve as the final borders of the door.)
Step 5: Glue the boards on the left and right sides of the door with the Wood Glue.
Step 6: Take the left over piece if the (1x10) board and lay across the middle of the door, about 4 feet from the bottom of the door. This board should be close to the center of the door but you can place it where you think it looks good. Cut the board to fit inside the frame of the door (approximately 27.5 inches). Then glue it down with the wood glue.
Step 7: Get the (1x6) board and lay it diagonal to make half of the X on the door. Mark a line where you plan to cut the board. I just laid it on top of the door and made the line using a straight edge. Then I cut it before I made the bottom line just to make sure I allowed for error. If you make a bad cut you can always use wood filler to fill in gaps. Once you have the board cut on both ends, glue it down.
Step 8: Get a (1x6) board and lay it on the door to complete the X shape. You will have to make 4 cuts here, so I recommend making a line with a straight edge and then make a cut. Once you make the first cut, lay the board back on the door and mark where you want to cut the next angle, then make the second cut. Repeat this process 2 more times making only one mark and one cut at a time to allow for error. Use wood filler to fill in any ugly cuts as needed. Once the boards are cut, glue them into place.
Step 9: The door is basically done so now you will use the 1 1/4 inch screws to screw all the boards into place. Put 2 rows of screws down the sides of the door to make sure that the door keeps its shape. Counter sink the screws a little to make sure they door not stick out at all. Use the wood filler to fill in the screw holes when finished.
Step 11: Allow the door to sit a few hours to let the wood filler completely dry, then sand the entire door focusing on the places where there is wood filler. Dust the door off as much as possible after sanding.
Step 12: Next, Apply a coat of white paint all over the door. Let it dry a few minutes. Apply a second coat of paint to the door.
You should have an extra (1x6) board left over. This will be used to hang the bard door hardware. Please follow the directions on the barn door hardware when hanging the barn door. I recommend having someone help you hang the door because it is heavy.