Sliding Barn Door: Build It

I’ve wanted a sliding barn door in our house since, oh I don’t know….forever. So for my birthday, Jon surprised me with the hardware to make our own.  Seriously!? He knows me so well.  Not many girls will get this giddy over hardware for a birthday present. I just can’t help it!

I’m breaking this how-to into a couple posts because it will get pretty lengthy.  First off: building the door.  Awhile back, we found some glorious old wood at the Habitat for Humanity Restore.

I had the idea back then to make a barn wood accent wall.  Then came the idea for the door.  It was a close race but in the end, the door took the cake (although we still have some wood left over for another project just waiting to happen).

When I first fell in love with sliding barn doors, I did a quick google search on the hardware and got a little discouraged.  At about $450 for just the hardware, I knew I couldn’t justify spending that any time soon (or probably ever).  While grumbling about my woes, a lovely reader brought up the idea to buy actual sliding barn door hardware…like for actual barns…from a place like Amazon. (Find out what to buy in this post).

We gave the wood a good scrubbin since it was pretty dirty.

We needed something for all of the planks to attach to so we cut some plywood the height/width of the door.

By the way, the measurements of the door were the measurements of our door frame, plus an inch on each side (top and sides).  We wanted to make sure the door totally covered the frame when it was shut.  We thought it might look a little funny if parts of the frame were showing.

I drew out what I wanted and started the building/cutting/gluing/nailing.

We started building the door back in January. I just noticed the Easter basket in the picture below.  I’m very puzzled as to why there is an Easter basket in our living room in January.  We didn’t even get Easter baskets out for ACTUAL Easter. I don’t even recognize the basket.

I’ll ponder this freaky phantom Easter basket and get back to you.

We initially used Liquid Nails to attach the wood to the plywood.  It didn’t work at all.  So, we used the wood glue we had on hand, with some nails for extra security and it worked great.  Lesson learned.

Once we had the frame where we wanted it, we used every heavy object we could find to add weight while it sealed overnight.  Yes, we might have even gotten a couple rocks from the woods to help out.

To get the herringbone-ish pattern we wanted, we cut the planks at 45 degrees on both sides with this miter saw.  We started in the corner and just worked our way up.

No, I didn’t clean my garage just to take a picture. Just keepin it real.

I was the wood cutter and Jon was the installer. What a team.

We even had our usual helper in his usual helper stance. (Usual stance = staring straight at us, not moving a muscle).

Seriously, our dog has a staring problem to the max.  It was a little creepy for the first couple months we got him. I would be cooking or something similar, minding my own business, then I turn around to do something, then BAM! I see a dog sitting in the corner perfectly still, staring me down.

“Oh hey buddy…what’s up?”
(Blank stare, statue-like, no blinking)
“Nothin? Ok…well…um… Did you see that cat earlier? He was just beggin to be chased”
(Blank stare, statue-like, no blinking)
“No? Ok…um…I’m going to…um…go to another room…because you’re being creepy”
(Blank stare, statue-like, no blinking)
(I slowly back out of the room)

But don’t worry, we’re totally used to it now. It would be weird if I WASN’T being stared down every. single. moment.

And again with the find-everything-heavy-you-can-and-pile-it-on:

After it was built, we gave it a good sanding…

Here it is all built, sanded, and ready for staining:

And after. We stained it a mixture of Dark walnut (which can be found here) and Provincial (which can be found here). Then, we sealed it with this poly.  Sorry for the harsh shadows, but I promise you some better pictures of the finished door will follow soon!

Check out the next part here!

                

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Comments

  1. says

    What a great tutorial. The door looks beautiful so far. I’m pinning this for future reference. Found you on the Addicted 2 Decorating link party. :) Your newest follower – Megan

  2. hikergirl says

    I LOVE this door! You and hubby did a wonderful job that I know couldn’t have been done without the supervision of the deep blue staring doggie eyes. They say… “Ya better get this angle right!”

  3. Cheri says

    What a creative design… love your door! Can’t wait to see the hardware and the cost. Maybe I can finally convince my husband this is the way to cover our hidden storage below the stairs!

  4. says

    I want to do a door in my kitchen. I sure hope you have a very frugal way of installing it! :)
    Great job so far, I love the look of your door!
    gail

  5. Shannon A says

    Great door & tutorial! Found you via Pinterest. And by the way, our cat does the staring ya down thing too. We call it “stalker kitty cat mode” :)

  6. Sara says

    Did you do the same pattern on the back of the door?

    LOVE it! We are going to do this in our home and this is the perfect tutorial.

  7. says

    Suzie,
    I’m sure you’re pretty busy, but if you could email me and tell me how thick your door is, I’d appreciate it. Mine is going to be about 1.5 inches thick. I’m thinking that the bracket is too deep for it.
    Thanks so much!
    gail at myrepurposedlife.net

    • says

      Our door is actually 1.5″ thick too. And it works great. Granted, if we hadn’t added the two 2x4s to the wall, the bolts would rub on the wall. But it works fine with a 1.5″ thick door.

  8. Barry says

    Did you use pressure treated wood for the outer frame of your herring bone pattern? If so has it bled through at all? If you did use pressure treated you might want to check with your local lumber yard regarding the use of pressure treated wood indoors. (not recommended) Just a word of caution………..

  9. Dave says

    Thanks for posting your project. Looks great! We have a doorway between our kitchen/family room and dining/living room. The noise from our five kids in the family room makes it hard to hear the TV in the living room so we wanted to somehow cover the doorway. This could be our solution! My concern is since we are trying to reduce noise should we make the door wider than 1” over the frame? Also, any “lessons learned” now that several months have passed since your installation? Thanks! Dave

  10. edmonton-industrial.com says

    Might you have further articles such as this one named,
    Sliding Barn Door: Build It? I just desire to read even much more about it.

    Thanks.

  11. says

    Thanks for your tutorial. I designed a sliding barn door, too, that many like. Next we will be making a pair of SCREEN doors for our screened porch off the deck. They will be made of treated wood and then stained with matching deck stain. The reason for two doors is so when we have guests, we can throw them open to allow for better traffic flow. Closed, they pretty much keep insects out. One thing readers might consider is to use biscuits when butting boards together, along with a good glue. The to be extra cautious, I will probably use some angle iron brackets of some kind. Thanks for the creative encouragement. Carpe diem!!

  12. Josh says

    We are making this door – it’s incredible!

    Three questions:

    1 – It looks like the plywood is 1/2″ thick right, is that correct?
    2 – What did you use for the trim around the outside of the door so that you dont see the plywood edge? It’s not super clear from the pics.
    3 – What color / brand stain did you go with?

    Thanks again! Amazing!

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