How to Make a DIY Rustic Barn Door

If you've researched "barn" doors in the rough, you're probably having a sticker scare.

See how to save your money by taking the do-it-yourself approach to building a barn door.

We hope you enjoy watching this video about Easy DIY Project Barn Door

Source: The Rehab Life

Time: Several days
Complexity: Intermediate
Cost: $ 251-500

Tools Needed

  • 3/8 in. little bunny
  • Tooth
  • Brush knot cup
  • Router
  • Standard DIY tools

Required Materials

  • 1-1 / 2 in. Forged Head Nails (40)
  • 1x6 x 8 ft. Pine boards no 2 (12)
  • Barn Door Hardware Kit
  • Polyethylene brush or roller
  • Dark spot (1 qt.)
  • Gray stain (1 qt.)
  • Knots brush for grinder
  • Light gold stain (2 qts.)
  • Polyurethane (1 qt.)

Step by Step Project

Step 1: Know your barn door hardware options

Before you start shopping for barn door hardware, take a good look at the area where you would like to install the door and find out which door configuration works best.

  • If you want to cover the opening with a door, you will need an area on one side of the opening that is wide enough for the door.

Pro Tip: Make sure there are no obstructions such as light switches, wall lights, or heating vents that could cover or interfere with the door.

If there is not enough wall space on one side of the opening, you can install a pair of doors that slide to opposite sides or purchase special bypass hardware that allows the doors to stack.

Step 2: Measure the opening

  • To determine the width of the door, add at least two inches to the width of the opening or the outside dimensions of the door edge.

Pro Tip: Sliding doors should extend at least one inch beyond the sides of the opening that are not finished or one inch beyond the frames of the finished openings.

You can add more overlays for more privacy.

  • Choose your barn door hardware before determining your door height. Consult the measurement instructions or ask the manufacturer for help in reaching the height of the door. In most cases, measure to the top of an untrimmed opening or to the top of the trim and subtract 1/2 in. your measurement will give you the minimum required door height.

Pro Tip: Make sure you leave enough room over the opening to lift the door and place it on the track. This distance varies depending on your hardware, so check with the manufacturer again.

Step 3: Three ways to support the trails

To support a door, the rail must be solidly mounted on the wall frame. There are three options.

  • Install a continuous wood bracket between the wall studs at the height of the track. This allows the freedom to install rail mounting screws in any location.

Pro Tip: This method is not practical in a finished room because you would have to remove the drywall or plaster to install the block.

  • Mount a collector plate on the surface of the wall (as seen in the photo above), making sure that it is screwed tightly to the pins, and screw the rail into the collector plate.

Pro Tip: A manufacturer recommends a maximum door weight of 75 pounds. if you are using this method because the bracket screws will only fit 3/4 in. wood. of thickness.

  • The third option is to bolt the rail directly to the joists. You have to do two things if you choose this method.

Make sure to order a blank rail first, as you will need to drill the holes at the stud locations yourself.

Second, ask the vendor to recommend hardware to avoid crushing the drywall. Most vendors have crush plates or something similar to solve the problem.

Step 4: Get the correct floor spacers and guides

Some types of spacers or spacers that hold the rail away from the wall, allowing the door to slide freely, will be included in the rail mount barn door hardware.

  • Some companies offer different length spacers, while others offer adjustable length spacers. The length of the spacers is determined by the rail mounting method, whether there are gaskets around the door or on the floor that you need to clean, and the thickness of the door.

Pro Tip: Be sure to check with the supplier before placing your order to make sure you are getting the correct length spacers for your situation.

Step 5: Roll guide

You will need a floor guide to prevent the bottom of the door from swinging.

  • The simplest guide is an L-shaped metal bracket that mounts to the floor and fits into a slot at the bottom of the door. If your barn door doesn't have a slot, there are roller guides and adjustable roller guides that will work. Choose the guide that best suits your door.

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