Custom Barn Doors

Published on 26 February 2024 at 06:05

We've been busy at the wood shop creating custom "barn" or sliding doors for two separate rooms in the house.  Being that each door opening was a unique size, the process enabled us to custom size the doors to our needs. 

Making sliding barn doors can be a rewarding and creative DIY project that adds a rustic and charming touch to your home. Whether you're looking to create a space-saving solution or simply want to enhance the aesthetic appeal of a room, sliding barn doors can be a stylish and functional addition. Here's a step-by-step guide to help you make your own sliding barn doors:

Materials:

  1. Wooden planks or panels (for the door)
  2. Plywood (for the door backing)
  3. Wood glue
  4. Wood screws
  5. Wood stain or paint
  6. Sliding door hardware kit
  7. Drill
  8. Circular saw or handsaw
  9. Sandpaper
  10. Measuring tape
  11. Pencil

Steps:

  1. Measurements:

    • Measure the door frame or opening where you intend to install the sliding barn doors.
    • Determine the desired height and width of the doors based on your measurements.
  2. Select Wood:

    • Choose the type of wood you want for your barn doors. Popular options include pine, cedar, or reclaimed wood for a more rustic look.
  3. Cutting:

    • Using a circular saw or handsaw, cut the wooden planks or panels to the desired dimensions for the doors.
    • Cut a piece of plywood to serve as the backing for the door.
  4. Assembly:

    • Lay the wooden planks or panels side by side, ensuring they align evenly.
    • Apply wood glue to the edges of the planks and press them onto the plywood backing.
    • Secure the planks in place with wood screws, ensuring a sturdy bond.
  5. Sand and Finish:

    • Sand the entire door surface to smooth out any rough edges or imperfections.
    • Apply a wood stain or paint of your choice to achieve the desired finish. Allow it to dry completely.
  6. Install Hardware:

    • Purchase a sliding door hardware kit, which typically includes a track, rollers, and other necessary components.
    • Follow the manufacturer's instructions to install the sliding door hardware on the wall.
  7. Mounting:

    • Attach the rollers to the top of the barn door according to the hardware kit instructions.
    • Hang the door on the track and ensure it glides smoothly.
  8. Test and Adjust:

    • Test the sliding function of the door to ensure it opens and closes smoothly.
    • Make any necessary adjustments to the hardware for proper alignment.
  9. Final Touches:

    • Add any additional decorative elements or hardware, such as handles or pulls, to enhance the overall appearance.
  10. Installation:

    • Mount the track on the wall according to the manufacturer's guidelines.
    • Hang the door on the track and make sure it slides smoothly.

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