DIY Barn Door for less than $100

[dropcap]I[/dropcap] cannot express how excited I am about this door! I was literally jumping up and down when it was finally done and installed. This was one of my most rewarding DIY projects yet. Ever since the beginning of browsing Pinterest, I knew I would have a sliding barn door in our home. When our house was being built and we chose the floor plan, we noticed there was no door between our master bedroom and master bathroom. It is actually common in new build master suites and I knew that this would be the perfect place for a barn door.
 
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Okay so here is how I did it – we had some old fence boards from our old house that I made Joe save for me because I knew one day I could use them. I knew this weathered & light weight wood would be perfect for a door. Since we moved to our new house they have been sitting in a pile getting more weathered, rustic, and beautiful, so I guess it turned out for the best that I waited a whole year to start this project.

DIY BARN DOOR

SUPPLIES:

 

• • 1x4x8 plywood
  • fence boards, new or old
  • tape measure
  • level or straight edge
  • miter saw or jigsaw
  • nails & hammer, or nail gun
  • stud finder
  • drill & drill bit
  • hanging hardware
  • box rail
  • box rail brackets
  • stain, color of choice

 

I went to Tractor Supply Co. and bought all the hanging hardware. They actually have everything you need and even have an example set up with everything labeled and explanations on how it works. However, I found everything much cheaper on Amazon.

I knew I would need a piece of wood to attach the boards to, so I measured the opening of the doorway and added an extra six inches or so for the sides. I went to Lowe’s and an employee helped me find a light piece of plywood. I didn’t want anything too heavy because of the extra weight with adding more wood and the height. Most sliding doors are probably standard door height, but this one needed to be 8 feet tall! The employee cut the plywood for me according to my door measurements.

 

 

Using nails instead, I was able to attach the boards in the middle, sides, and every corner without them being noticeable. This also helped in the center of the door with my herringbone pattern.

 

There is nail about every three inches on the sides of each board. Next, I sanded down the door to clean it up some and prepare the new wood for stain. I used Minwax Classic Gray, Weathered Gray & Special Walnut stain to match up the new wood with the old. I use stain almost like paint sometimes to match up colors. I also stained the back of the door, knowing the back can be seen from inside the bathroom.

After the stain dried, it was time to attach the hardware. The instructions that are included can be a little hard to follow, but once the hanging hardware is together – it should look like this:

I  measured six inches inward from each side and marked it. Then I marked the three square holes where I pre drilled the wood. I inserted the bolts and tightened the nuts on the back.

I used a stud finder to find three studs in the wall and pre drilled the holes. When Joe came home from work, he helped me finish installing the box rail and then he hung the door. This part was a little tricky – the door was so heavy that it took both of us to hold and the wheels have to be lined up just right in order for it to slide in. A few bangs with a hammer and we got the first wheels in and the second wheels followed right behind. Then Joe installed the end caps.

 

It slides very easily, but the door was kind of dragging on the carpet. It was fine, but we knew that after awhile it would really wear the carpet down. We should of installed the box rail just a couple inches higher. Instead of taking it all down, patching holes, and drilling new holes I grabbed the jigsaw and Joe cut an inch or so off the bottom of the door while it was hanging.

 

 

This was the first major project for our master bedroom makeover and I’m so happy with how it turned out. Like any DIY project, at times it wasn’t easy but it all worked out in the end. Next, I will begin painting and I have plans for some new nightstands and lamps. Can’t wait to share!

 

Are you going to tackle a sliding door? Share with me!

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