Have you ever wanted to build your own barn door but you aren’t into the barn look? Here is a simple tutorial on how to build one yourself. I promise it is easier than it seems!
Supply List – Note: I make a small commision from affiliate links
- 3/4″ 4’x8′ Sheet Sanded Plywood
- 1 – 1″x6″x8′ Primed Pine
- 2 – 1″x4″x8′ Primed Pine
- 3 – 1″x2″x8′ Primed Pine
- **2 – 3/16 in x 24 in x 32 in Primed White MDF Beaded Wainscot Panel
- Wood Filler
- Barn Door Hardware
- 1 1/4″ Brad Nails
- 3/4″ Brad Nails
**Please Note that if you are designing a larger door, you may need a larger sheet of beadboard.
- Miter Saw or Circular Saw
- Circular Saw or Table Saw or Jigsaw
- Measuring Tape
- Nail Gun
- Drip Free Caulk Gun I highly recommend you have a drip free caulk gun to save yourself a lot of headaches!
- Wood Glue
I think a lot of people think it is going to be difficult to build a door, but the truth is, it is actually very simple!
The most important part is to choose a dimensionally stable base to build your door on. I used 3/4″ plywood, but 3/4″ MDF would also be a great choice if you are painting the door! I once built a couple barn doors using tongue and groove boards and then trimmed them. They looked amazing and I was incredibly proud of them, however after about 6 months as the boards adjusted to the temperature and humidity inside the house one of them warped and now they look twisted and terrible!
The first thing you are going to do is decide how large your door needs to be. It should be a couple inches wider than the door opening, but also take into account if there is limited space in the direction the door is sliding to open. Once you determine how large your door needs to be, subtract 1.5″ from the width dimension and 1.5″ from the length direction. Then cut your plywood sheet down to that size. I cut my sheet to 31″x89″. Then cut 2 pieces from your 1×6 boards to the same width as your plywood sheet and two 1×4 boards the length of your sheet minus 11″ (to account for the 2 1×6 boards you will place on the top and bottom. Glue and nail the 1×6 and 1×4 boards to your plywood sheet.
Cut another 1×6 board to size to fit in the middle of the door between the 1×4 boards. My board was cut to 24′. Dry fit the board in the center of the door and measure the two panels. You could omit the beadboard at this point if you like the look of a flat panel door or add your own flair to the panels! This is your chance to add your own ideas or design aesthetic! It is also important to note that if your panels are larger than 24″ wide or 32″ tall, you will need to buy a larger sheet of beadboard. Measure the panel openings and cut your beadboard panels to size using a table saw or a miter saw. Insert the panels and the center 1×6 board and glue and nail them into place. Use 1 1/4″ nails for the 1×6 board and 3/4″ nails for the beadboard panels.
Now it is time to frame the edge of the boards with 1×2 boards. The actual size of the 1×2 boards is .75″ x 1.5″ so the width of the board is almost the same size as the 3/4″ plywood and 1×4 and 1×6 boards together. Measure the length and width of your door and cut a piece with 45 degree mitered edges for each side, measuring short end to short end (see figure below). The miter should be cut with the board on its’ side across the 3/4′ thickness.
Then glue and nail the 1×2 boards around the edge of the board. For some reason, my boards were about 1/16″ wider than my door, so instead of trying to make the boards flush, I made the backside flush with a 1/16″ reveal on the front side. You can see in the picture below, the edge boards sit slightly above the top of the door boards.
Now you will need to fill in all nail holes and joints with wood filler and caulk between the boards and the panels.
After the wood filler is dry, you can sand the excess wood filler smooth and then your door is ready to paint! My door is painted SW Shadow Pink. The last step is to hang your door using the barn door hardware kit that should come with directions. If I don’t respond, try again! I’m sure I just missed it! Congratulations! You built a barn door. I knew you could do it! Feel free to reach out with any questions. I am most easily reached through DMs on Instagram or by email at [email protected]