For this project you will need a drill, a circular saw, a wrench, a brad nailer, and a table saw. A miter saw and an impact driver will also make this project easier.
2-3 shipping pallets or a few large shipping crates should provide enough wood for a barn door.
Pulley wheels, rails, and hardware will get things rolling! We were able to find all of our hardware at nearby Home Depot and Grainger stores.
Step 1: Parts to Cut
Reclaimed pallets, skids, shipping crates, and the like can provide a variety of lengths, widths, wood grains and colors to work with. For our reclaimed sliding barn doors, we used the dimensions shown.
Step 2: Get Movin' - You Make a Better Door Than a Pallet
Make sure your stagger is right and you measure for a door that hangs properly.
We were able to find reclaimed wood that was fairly straight (or sanded and planed out without to much effort). You'll want the support pieces to be as straight as you can get them - If not, you can cheat a little and used new boards just for this step.
Step 3: Attach Support and Hardware
Image shown: Attaching the straight bar the wheels will glide on.
The trickiest and most time absorbing task here is getting the rails just right.