DIY Double Sliding Barn Doors for Pantry

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About: Hi Everyone, I'm Jeremy Hoffpauir. I write instructables about unique DIY woodworking and home improvement projects. I use unique design elements with a rustic coastal style in my creations such as epoxy...

Step 1: Straight Sides

In order to get 2 straight sides on each of the 4 walnut panels for the double sliding barn doors, I used my festool track saw.

First, I lined up my track saw about 1″ from the edge and made a cut. Next, I referenced the straight line I just cut, measured the final width of the board, and made another cut. Keep in mind, I purchased these boards as S3S (Surface 3 Sides) lumber. Essentially, this means the wood was planed on both surfaces and one side was straightened. However, I like to make certain each board has straight sides.

Step 2: Joinery Method Used

I used my festool domino DF 500 to join the DIY double sliding barn doors. Additionally, I recommend using dowels or biscuits as an alternative joinery method.

First, I placed the boards next to each other and loosely clamped each end to hold them together. Next, I used my tape measure and combination square to mark a straight line every 12″. Also, I put diagonal line next to each join in order to know which of the 4 boards would have dominos on each side. Quick Tip: I always place a domino, biscuit or dowel 3″ from each end.

Then, I lined up my domino with the lines and cut the mortise. Furthermore, the same process applies to a biscuit joiner and dowel jig.

Step 3: Apply Glue and Dominos

Before I spread glue, I placed each board next to one another as I did in a previous step when I made the marks.

First, I liberally spread glue on each edge. Next, I inserted the dominos and used my glue spreader to wipe glue on them. Then, I joined the first two boards by pushing them together and I made certain they were snug.

Quick Tip: Edge Joining Panels

To make edge joining panels for this DIY double sliding barn doors, I join 2 boards at a time. Since each DIY barn door has 4 boards, I join each of the 2 outer boards. Then, I join each pair to each other. Ultimately, I find this process helps ensure the panels remain flat.

Step 4: Glue Up

Once I glued each door, I clamped them together and let the glue dry for roughly 4 hours.

Next, I removed the clamps and used my glue scraper to remove any excess glue. If you applied glue and clamped properly, you should have a small amount of excess which squeezed out.

Step 5: Sanding

Love the process or loathe the process, sanding is vitally important to woodworking project.

Essentially, I followed the same sanding process for these DIY double sliding barn doors as the matching DIY Walnut dining table project. Visit that post for more detail.

Step 6: Outer Stile and Rail

To make the flat wood panels look like barn doors, I used an ‘H’ design pattern. Essentially, this design consists of smaller boards around the perimeter and one perpendicular board in the middle.

I verified my measurements on each panel and cut the boards to size.

Step 7: Secure Outer Stile and Rail

I used my speed square to keep the vertical and perpendicular boards square.

While holding the square in place, I clamped each board in place and used my brad nailer with 1″ brad nails (2 per board) from the underside of the DIY barn doors to hold everything in place while the glue dried. Furthermore, the underside of the double sliding barn doors will not be visible which is the reason I drove the brad nails from the underside of the barn doors.

Step 8: Rubio Monocoat Finish Application

Due to my careless error, I do not have video footage of the barn door finish process.

In summary, I applied the finish at the same time and using the same procedure as the Walnut dining table.

Step 9: Sliding Barn Door Hardware Kit

After I the rubio monocoat finish dried, I installed the hardware for the DIY double sliding barn doors.
Essentially, I installed 3 pieces of barn door hardware.

I forgot to mention earlier in the article that I cut a 84″ x 4″ piece of walnut to hold the rail. Also, I secured this piece of Walnut to the studs on the wall before installation.

First, I used this sliding barn door hardware kit. The kit comes in different sizes – I chose the 6.6′ kit. Furthermore, I used 2 kits because a single kit contains the hardware for 1 door (2 rollers and 1 rail).

Step 10: Barn Door Magnets and Bumpers

After I completed the installation of the barn door hardware kit, I decided to use these neodymium magnets to keep the barn doors closed.

Next, I used my drill and a 1.5″ forstner bit to recess the magnets in each door. Additionally, I used clear cabinet bumpers to prevent the barn doors from slamming together. These magnets are super strong.

Step 11: Barn Door Floor Guide

For the last piece of barn door hardware, I installed a barn door floor guide to prevent the barn doors from swinging out.

Keep in mind, the DIY barn door floor guides are not required. Ultimately, it keeps the barn doors aligned and prevents them from hitting the baseboards when they are opened and closed.

Step 12: Conclusion

I hope this project provided you with value.

Visit my online store to download a set of DIY Plans or purchase unique items I create.

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