DIY BARN DOOR
Thank you for being patient, and waiting for this post on our DIY barn doors! If you follow me on Instagram you saw a behind the scenes peak at my husband and I building the barn doors for our home office. During that process I received several requests for a DIY Post on all the steps we used to create the doors. Here is that Post!
We used one $35 sheet of plywoodfor each door. We were able to get all the cuts we needed to create the door and trim for each side of the door, with the exception of the bottom trim piece for one side…We had a scrap that worked from a previous project. If you don’t you can buy a small piece of 1/2″ wood to create that piece. At home depot in the wood trim department they sell smaller inexpensive pieces of plywood.
I went ahead and linked the exact saw and nail gun we have. You could do this project with a smaller saw and regular finish nails and a hammer. But if you already have these tools it makes it a faster process. We have done several DIY home projects and these are the tools we use for most of them
STEP ONE-PURCHASE AND CUT PLYWOOD
Purchase your plywood, and then have the lumbar store (we bought ours at Home Depot) do all the major cuts for you. They have a huge saw and it’s so much faster if you have them cut down the plywood into the sizes you need. Below you will find a diagram of the sizes you will need them to cut for you.
NOTE ABOUT THE PLYWOOD
The plywood we choose is a lower grade plywood, there are different grades of plywood and if you want to spend a little more per sheet you can purchase one of those. The only thing we noticed with this plywood is it was best not to sand the flat parts. The edges were okay to sand and smooth but if we took sand paper to the flat surface it made it almost fuzzy…I’m not sure why but I assume if you used a higher quality plywood it would be made from a harder wood and you can sand it. Overall the flat parts really didn’t need any sanding so it’s better to not touch it and just sand the edges.
Below I labeled where you will use those pieces as you build your door. If you have them do all of the cuts listed you won’t need a saw for the project. We used it to trim down our scraps to create the bottom trim piece we weren’t able to get out of the large sheet of plywood. We also cut the cross piece and top piece to size at home.
STEP TWO-ATTACH TRIM PIECES
The trim is what makes it look like a door. We did a simple design, framed the door out in trim, and added one center cross trim piece.
STEP THREE-WOOD FILLER
Once the trim is attached you will fill in all the nail holes. I also took the wood filler, and a putty knife and then picture frosting a cake, I ran a thin layer of putty all down the side of the door. The wood filler fills in where the ridge of the trim pieces sandwich the door. We used plywood so it also fills in any little divots or along the edge of the door.
STEP FOUR-PRIME AND PAINT DOORS
I used a THIS PAINT SPRAYER to prime and paint the doors. I’ve used this sprayer several times and it gives your wood projects such a smooth finish and professional look. I painted the doors in my garage and I absolutely LOVE THIS PAINT TENT for my painting projects. It’s so large I can stand in it and it protects the surrounding areas from over spray.
STEP FIVE-HANG THE DOORS
We got our door hardware from THE BARN DOOR HARDWARE STORE. The track kit comes with complete hanging instructions. We needed an 11′ track and chose their MODERN ROUNDEDHANGER. I just noticed they are offering free shipping until 2/27/18. We hung the track and then decided on what sizes doors we needed to make, but you could decide the door size and then hang the track accordingly. You just want to make sure the doors cover the door frame trim.
I hope you find this helpful! It took us a full day to build these two doors. But our doors cost $40 per door and if you were to purchase a door it would be anywhere from $200-500 a door. So if you tackle this DIY you will save A LOT of money!
You can see from the pictures we still have the original trim up for french doors that use to hang in this space. We plan on popping that off and framing out the door with some plain flat trim. I’ll update a picture once that’s done.
This was step one of our home office makeover, stay tuned for more!