For this project, I wanted to replace broken slide doors for the bedroom closet with barn doors.
This is my first attempt to build barn doors.
That is why I tried to keep the design as simple as possible.
Step 1: Tools & Materials
Miter Saw or 7-1/4 in.
Circular Saw ( I usually prefer Miter to make straight cuts)
Various small Drill bits
Countersink drill bit
Kreg Jig Mini (I love this one, Plus it was prize from Instructables.)
Another option is Kreg K4MS Jig Master System
Screws: 1-1/4 in. drywall screws
Kreg 1-1/4 in pocket-hole screws
8 pcs (1 in. x 6 in. x 8 ft.) Premium Kiln-Dried Square Edge Whitewood Common Board $7.87 /each
14 pcs (1 in. x 6 in. x 8 ft.) Premium Tongue and Groove Pattern Whitewood Board @ $4.54/each
4 pcs (1 in. x 2 in. x 8 ft.) Trim Board Primed Finger-Joint @ $2.98/each
An approximate materials cost for building two barn doors is $160 plus cost of barn door hardware, for which cost varies.
Step 2: Cut Pieces for Door Frame
In my case, I want to cover the closet door opening with two doors.
Each door is going to be 83 in. tall and 37 1/2 in. wide.
Cut door frame:
For this, I used 1 in. x 6 in. x 8 ft common board and cut two sides @ 83 in. long and two top and bottom in between pieces @26 1/2 in.
To make each door 37 1/2 in. wide, I subtracted two board width (sides).
They are 5 1/2 in. wide each, which makes the middle 26 1/2 in. long.
Step 3: Create Pocket Holes
Using Kreg Jig, I secured it to the board with clamp and drilled holes for the pocket hole screws to secure the frame together.
There are two pocket screws per each side of the board.
At same time I also cut the channel for the bottom since the barn door kit comes with the floor guide.
This is just a 1/4 in. deep by 1 in. cut for the bottom pieces of the door.
Step 4: Put Door Front Together
I secured the sides to each other only using 1 /14 in. pocket screws. This was just to ensure proper fitment, since I will take it apart and use wood glue after measuring and cutting the cross bar.
Step 5: Create Crossbar
For the cross bar, I marked the middle of the board on top and bottom and slid it under the frame.
This will allow me to mark where the board needs to be cut so it can fit as cross support within the frame.
Since I have two doors for one door cross beam will go to the right and on another door it will go to the left.
I cut the boards as marked to ensure tight fitment withing frame.
Then using Kreg Jig and drilled pocket holes on both cross bar and the frame.
Step 6: Assemble the Door Frame
Put the frame together. I took the frame apart then attached the sides with pocket screws and a little bit of wood glue. Since side facing down is what will be front, we do not want excel glue to leak to the front.
Then I attached to cross bar with a little bit of wood glue and pockets screws as well.
Step 7: Assemble Door Back
Assemble back with 1×2 in and tongue and groove boards.
I cut all tongue and groove and 1×2 in. boards @ 83 in. long just like door height. Then attached 1×2 in. board to the edge as starting point. This will allow me to hold tongue and groove boards in the middle. We will attach another 1×2 in. board to another side edge.
To make tongue and groove boards fit together I used rubber mallet so they will lock into one another.
Step 8: Drill Pilot Holes and Countersink Holes
Since these boards would crack if we just drive 1 1/4 in. screws to secure them to the door frame. I first pre-drilled all the holes and use countersink drill bit. I pre-drilled two holes per boards for the top and bottom.
For the sides, I spaced screw holes about 1 foot apart
Step 9: Cut Tongue and Grove Boards to Fit
Because tongue and groove boards will not perfectly fit the width of the door, I had to cut 1 in. from one of the boards to make it fit.
Last picture has barn door dry fitment before we secure it to the frame.
Step 10: Permanently Secure All Backing Boards
I lifted the tongue and groove boards out and applied wood glue.
Then lowered the boards and screwed them in. In addition, I drilled pocket screw holes for the cross bar and screwed them in using 1 1/4 in. drywall screws.
Step 11: Allow Time for the Wood Glue to Dry
Allowed some time for wood glue to dry and assembled second door
I also had leftovers pieces, since boards were longer than required.
I’m certain I can find a use for them down the road.
Step 12: Install Barn Doors
For hardware, I used a kit from amazon that made it very easy to install.
TMS TSQ09-ORB(2SET)+CONN-ORB Antique American Country Style Double Sliding Barn Door Hardware Set @ $100 for two doors.
This was one of the easiest parts. Since there is existing header above closet door. I just had to measure and screw the door hardware level above the doors. Door sliders bars were a longer then needed, so they were trimmed with angle grinder.
Then I attached old doors first just to see how it will look, before securing the barn doors.
Thank you for checking out my project. To see more of my work visit Darko.us