DIY Sliding Barn Door

DIY Sliding Barn Door

Use Carpenter David Leon’s instructions to build a sliding barn door for your closet.


5 col

Separate one open room from another with a chic sliding barn door that will add style and function to your space.

Materials
(2) 3-foot hollow core interior doors
(2) Metal strap ties
1-inch nails
Jigsaw
1” x 4” Pre-cut lumber (4) 80”, (2) 27”, (1) 76 1/2”, (1) 65”
1” x 1” Pre-cut lumber (1) 7”, (1) 12”
(2) Decorative sliding door hardware kits
Screwdriver
Drill and 3/8-inch drill bit
(2) Heavy-duty decorative tee hinges
Level
Pencil
Tape measure
Semi-gloss interior paint
Paintbrush
2-inch interior screws
(2) 1” x 3” x 6’ 2” boards
Stud finder

Instructions

  1. On a flat surface, lay your hollow core interior doors side by side so that they are flush together
  2. To make sure that the two doors securely stay together, place a strap tie on the bottom and top where the two doors come together. Have a friend hold the doors together to keep them from moving while you nail the strap ties in. Place a strap tie and nail it in using your hammer and 1-inch nails in each hole

  1. Repeat step 2 on the bottom side of the two doors, so that the doors become seamlessly secured to one other. You now have one large “barn” door that will slide on a track
  2. Next you’ll need your (2) 80”, (2) 27½”, 65”, 76 ½” pieces of wood

  1. Start with (1) of your 80-inch pieces and apply wood glue to one side. Place it on the far left side of the face of the barn door so the outside edges are aligned with the edges of the door. Hammer in nails in the corners and down the side

Tip: Hollow core doors have 11/2-inch border of wood inside the doors so do not hammer past this mark — there is no material to receive your nails past this border.

  1. Next apply the 65-inch board with wood glue and nails along the bottom of the barn door followed by other 80-inch piece to the right side of the door. Put 2 nails in the top and 2 nails in the bottom and then evenly space 5 nails going up the right side of the 80-inch piece
  2. With the 76 1/2-inch middle piece, find the center point on each end and make a mark for the top and the bottom. This will make it easier to line up with the center of the door
  3. Apply wood glue to the side of the 76 1/2-inch board that you didn’t mark. Line up your marks with the center crease where the two doors come together. Hammer in two nails to the corners at the top and two in the bottom, and down the length of the board. Be sure to alternate nails on different sides of the crease so both sides of the door are attached
  4. For the remaining 27 1/2-inch pieces you’ll need one of your door hangers from the decorative sliding door hardware kits. We will use this as a spacer to correctly place the 27 1/2-inch pieces. On the left side of the doorframe lay the door hanger flush to the right of the 80-inch piece at the top. Next, lay the 27½” piece horizontally against the door hanger while keeping the long edge of the piece flush with the top of the door. Remove the door hanger and mark where both ends of the 27 1/2-inch piece lie on the door
  5. On the right side we will again place a door hanger on the left of the 80-inch piece to mark the correct spacing for your 27 1/2-inch piece. Now use wood glue and nails to secure the 27 1/2-inch pieces to the doorframe on your marks
  6. With your remaining (2) 80-inch pieces, lay them diagonally starting in the top left and top right and then meeting at the corners at the bottom in the middle
  7. To cut the diagonal pieces to fit, mark each spot on the diagonal pieces where the existing wooden frame pieces are overlapped. The diagonal pieces are also lying over where the door hangers will go so use a door hanger as a guide to trace the area that is covering the door hinge. Once you have your marks made, carefully cut along your marks with a jigsaw
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  1. Test the fit of the diagonal pieces, and sand down any rough edges for a perfect fit. Attach the diagonal pieces to the door in their respective placements using wood glue and nails for the length of the pieces
  2. Use the wood glue to adhere the 7-inch and the 12-inch pieces of 1” x 1” wood to the frame. On the left side next to the 80-inch piece, glue the 12-inch piece 18 inches up from the bottom of the frame and on the right of the vertical 80-inch piece. Glue the 7-inch piece 18 inches from the top and on the right side of the vertical 80-inch piece. These pieces will hold our decorative door hinges, and will give us something to screw them into

  1. Paint your door the color of your choosing with semi-gloss interior paint and a paintbrush (We chose white for our door)
  2. To install the door hangers you’ll need to measure 1 1/2 inches from the top of the door in each of the four spaces you left for the hangers. Once you’ve marked those spots, place the hangers so that the top hole of the hanger is on the 1 1/2-inch mark. With a drill and a 3/8-inch twist bit, pre-drill holes through the holes on the hanger and all the way through the door
  3. Bolt the hangers through the door using the bolts and instructions provided in your decorative sliding door hardware kit
  4. On the left side of your barn door where you glued the 7 and 12-inch pieces of wood, attach the heavy-duty decorative tee hinges. Use (6) 1-inch screws per hinge to attach the hinges

Note: The decorative hinge on the 7-inch piece will extend all the way over the diagonal piece. (See picture below)

  1. Measure 40 inches up on the right side of your barn door and screw in the handle from your sliding door hardware kit on the 80-inch vertical piece using a screwdriver

Installing the Rack

  1. First, we need to make a straight line for our track. Above your doorframe, measure from the floor 81 3/4 inches up to the wall, and make a mark that is 2 inches left of the doorframe. Use your level and mark a straight line 150 inches across this height, extending past the doorframe. This will allow you to close the door with no gap between the door and the doorframe
  2. Find the studs along the 150-inch space using a stud finder and make a mark for each one.
  3. On your (2) 1” x 3” x 6’2” pieces of wood, draw a line down the center of the boards’ length. Match up the line on your boards with the line on the wall. Use 2-inch interior screws to screw the board to the wall but not through the studs (these are decorative pieces and lend no support until we bolt the track to the wall and studs). Use a level to make sure your board remains horizontal before each screw goes in
  4. Predrill 1/4-inch pilot holes in the middle of the boards you just hung where the studs are, going into the studs
  5. Bring your pieces of track up one at a time. Using the bolts and spacers from the decorative sliding door hardware kit, put the spacers behind the track and screw your bolts from the outside of the track, through the spacers, the decorative wood, and into the studs (spacers allow your track to stick out from the wall so your door can hang freely). Repeat this until the entire track is up, while using a level to maintain a perfect horizontal
  6. Have a friend help you lift the barn door and rest the wheels of the hangers onto the track

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Cathy

Reported

Such a great idea. Will be making this.

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