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What you'll need:
TOOLS
Miter saw
Power drill and drill bits
Power sander
Pocket hole jig (optional)
Extendable clamps
Stud finder
Level
SUPPLIES
16) 1-by-4-by-8 boards
Wood glue
Wood filler
Interior wood screws
Wood stain or paint
Barn door hardware kit
Metal handles
This just in: barn doors are having a moment. Whether you appreciate the sliding style or you want to bring your closet door idea to life, a barn door is a catch-all solution for many home renovation projects. Having a barn door built and installed by a pro will cost between $400 and $1,200, so you can save money by tackling it yourself. Read on for how to build a barn door in this comprehensive DIY guide.
Prepping to Build a Barn Door
The first thing you’ll need to do is choose the wood you’re going to work with. You can save some money and keep your door lightweight by choosing common pine, or you could step up the durability and appearance by opting for a hardwood. You could also opt for plywood for the backing instead of wood slats. This will change the appearance but could save some money.
It’s also worth mentioning that you can customize the look of your door by choosing different size wood boards for the backing. Consider both the thickness and the width when deciding.
Additionally, you should purchase a barn door hanging kit that fits your space—they usually provide appropriate dimensions for the kit. You could build the door hangers, but they’re quite complicated, and buying a set is typically a much better option.
Cut Your Lumber As Needed
Photo: Viktor Cvetkovic / E+ / Getty Images
It’s a good idea to cut all of your lumber upfront, as doing so will speed up the assembly process. You’ll need the following pieces:
(13) 1-by-4 boards cut to your door height
(3) 1-by-4 boards cut to your door width minus 7 inches
(2) 1-by-4 boards cut to fit at a 45-degree diagonal across the top and bottom panels of the door
You may want to wait to cut the angled boards, as you can use your door as a reference after you build it to get the length and angles exact.
Use a Wood Sander to Remove Any Hard Edges
A powered wood sander or plain old sandpaper can help smooth out your door, especially when using repurposed barn door wood.
Sand down the faces of all of your boards and plywood, making sure to start with a low grit—like 150—and gradually move toward a higher one—320—to get a perfectly smooth finish. You can also knock down any sharp edges, which you might have if you’re using hardwood boards.
Stain or Paint, If Desired
Photo: Dusan Kostik / Adobe Stock
Before assembling your layers, use stain or paint on each individual piece of wood, as desired. Heritage colors that recreate that classic barn door look include weathered wood gray, cedar, cherry dark red, and espresso.
Line Your Boards Up to Ensure Proper Fit
Once cut and dried, lay your boards out on a flat surface like a garage floor or driveway to ensure they fit together.
It might benefit your build to save the diagonal boards until you've lined these up to measure the diagonal beam. This will ensure a proper fit. For uneven wood, you may need to make a slightly different angular cut so that everything fits snugly.
Glue Layer One Together
Photo: Westend61 / Westend61 / Getty Images
Layer one consists of 13 boards laying side by side that'll form the foundation of your DIY barn door.
Apply wood glue liberally to each end and press to seal the pieces together. Use adjustable clamps to hold them together. Most wood glues take about 12 to 24 hours to dry, so tackle this portion in a room or area with low foot traffic.
If you have a pocket hole jig, it’s a good idea to use pocket holes to attach these pieces, as this will ensure a tight, straight fit.
Glue Layer Two Together
Layer two comprises of a frame that'll support the boards you've laid down. You can glue this directly to piece one (or build it separately and let it dry), then attach it with wood glue. If you build it separately, be sure to use pocket holes to attach the pieces.
If your wood is slightly uneven, it's probably best to build the frame separately and then attach the pieces.
Cut Your Diagonal Beam, Then Attach
After the wood glue has dried, line up layer two over layer one. Take measurements with the final beam to cut the diagonal piece accurately, then make those cuts with a miter saw. Make sure to account for the 45-degree angles you’ll have to cut on both ends of these boards.
Use wood glue and interior wood screws to secure everything in place. You can reinforce the diagonal beam at the top and bottom with a screw on each end if you wish.
Install a Backer Board to the Wall
While your wood glue dries, install the backer board (1-by-1-by-8 board) to cover the length of your door frame with at least the full space of the door frame to the left or right side.
For indoor drywall, make sure you use a stud finder to locate the wood beams in the wall and drill into those areas to secure it. You’ll want to use a level to check your work as you complete each step.
Install the Sliding Track Kit
Photo: Bill Oxford / iStock / Getty Images Plus / Getty Images
You can find a sliding track kit for a barn door for around $60 if you look online (this might not cover shipping costs) or at home improvement stores near you. Track kits come in different colors and textures, so pick one that complements your aesthetic and the style of wood you're using. Also, determine if it’s compatible with the thickness of your wood materials.
Honestly: it's fun to DIY build a barn door, but these kits make life much easier, and they bring down your overall door installation costs. Consider one of these instead of trying to build your own sliding track.
Most metal barn door sliding track kits come with a metal bar and separating bolts to create space away from the wall for the door to slide. Install these to the backboard, then attach the metal track according to the instructions.
Mount Your Barn Door to the Sliding Track
Once your barn door dries, it's time to mount it and test. Read the directions for your barn door kit. Most have metal track hooks that hang down and drill directly into the double-layer portion of your door.
Once the tracks are secure, test the door to make sure it slides the way you want it to—make adjustments as needed.
Install your Handles
Last but not least, mount the handles to the door. Creative ideas include a ring flush barn door handle, a leather pull, or just a basic single door handle you can get at a home improvement store.
DIY vs. Hiring a Pro
Building a barn door is a satisfying project that'll stretch your DIY muscles. But the sense of accomplishment and the fact that you'll save several hundred dollars over professional barn door installation costs makes this a suitable project for homeowners who are up for a challenge.
On the other hand, doing this project the right way requires using a handful of power tools, and actually hanging the door so that it’s level and opens and closes properly can be tough. You may want to hire a local door installation specialist to get that portion of the job done and make your life a little easier.
Frequently Asked Questions
You can use a variety of wood to build a barn door, but the most common options include 1-by boards and 2-by boards for the backing and the decorative boards on the front of the door. Softwoods like pine will save you some money and should hold up well, while hardwoods like maple and oak will stand up to more wear and tear. You could also build the backer out of plywood to minimize the cuts you need to make. Whatever you decide on, make sure the width of the wood is compatible with the mounting brackets you buy.
No, barn doors don’t always need a bottom track, especially if you buy a high quality top track that stabilizes the door. Bottom tracks can be helpful, though, to prevent the door from pushing inward or outward and potentially getting damaged. If you want your door to offer some security, then a bottom track is a good idea.
Yes, barn doors can be too heavy, although the limitation is usually imposed by the mounting hardware you buy and not your home’s framing, unless you’re building an unusually wide door. To keep the weight down, you can opt for 1-by material rather than 2-by material, and choose a softwood like pine rather than a hardwood like maple or oak. Check the weight limits on your mounting hardware, and always attach your door track to studs rather than to drywall anchors.
Dan is a writer and property manager and can be found sharing his home improvement tips on sites like EcoWatch and Today’s Homeowner. He loves sharing his years of hands-on experience and love of DIY to help homeowners bring their visions to life.
Dan is a writer and property manager and can be found sharing his home improvement tips on sites like EcoWatch and Today’s Homeowner. He loves sharing his years of hands-on experience and love of DIY to help homeowners bring their visions to life.
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