DIY Barn Door and DIY Barn Door Track That Won’t Break the Bank!

Happy Monday!

We’re officially calling this week Barn Door Week! Read on to find out why…

Dean and I have honestly been thinking about building a sliding barn door for our house for years. But it always sort of just fell to the bottom of the to-do list that is perpetually a mile long. To say we finally got to cross it off the list and are enjoying our barn door is an understatement!

UPCYCLED BARN DOOR no title

We were initially going to use reclaimed barn boards for our door. After all what better project to use barn boards for than a barn door?! But when we went to look at them at a shop in the city they were about $20 a board and really rough to the touch. I’m talking snag-your-best-sweater-from-a-foot-away kind of rough.

barn boards

Time for Plan B. 

Fortunately Dean had a couple of really chunky wood pallets at his work that his company wasn’t using anymore. He dismantled them and chose fifteen of the straightest boards. They were dinged and worn and full of character, but they weren’t all wonky and warped, if you know what I mean.

Next up – the rails.

RAIL AND WHEEL

One of the reasons we always let this project drop to the bottom of the list was figuring out the rail and wheels for the sliding action. This time my most talented hubby thought of using two of the kids’ broken scooter wheels minus the rubber and tubing!

And the handles.

Oh those beautiful handles! Again our initial idea wasn’t quite what we wanted (purchased handles). So we decided to DIY some really large handles using pipe fittings. And we fell in love!

LIVING ROOM 2

Also, aside from its beauty, our Reclaimed Barn Door actually helps to keep some of the kid noise out of the living room when we have company too. Bonus!

So are you ready for the tutorial? Like I mentioned we’re calling this Barn Door Week. Each day this week we’ll show you one part of the tutorial. All parts will be linked to this post for easy reference. 

Go gather your supplies and materials and get ready!

PLEASE NOTE: You will need to measure your own doorway and make adjustments to the measurements to fit.

T BREAK THE BANK

Materials

  • scooter wheels (with rubber removed) or pulley wheels (disassembled pulleys) qty=2
  • 1-1/4″ x  1/4″ x 86-1/8″ long steel flat bar qty=2
  • 1-1/2″ x 1/4″ x 84″ long steel flat bar qty=1
  • 3″ x 1/8″ x 84″ long steel flat bar qty=1
  • 1/2″ x 1/16″ x 2″ long steel tubing qty=7
  • 2″ x 6″ x 48″ long wood qty=15
  • fitting black iron floor flange 1″ qty=4
  • fitting black iron 90 degree elbow 1″ qty=4
  • black steel pipe nipple 1″ x close qty=4
  • black steel pipe nipple 1″ x 16″ long qty=2
  • 1/4″ x 1-1/2″ long plated lag bolts qty=60
  • 5/16″ x 3-1/2″ long plated lag bolts qty=7
  • #12 x 1-1/4″ long screws qty=16
  • 5/16″ x 2″ long – 18 thread plated hex bolts qty=2
  • 5/16″ – 18 thread plated hex nuts qty=2
  • 5/16″ plated flat washers qty=4
  • Minwax Dark Walnut stain
  • Rust-Oleum Oil Rubbed Bronze spray paint
  • white or light grey paint
  • water
  • sandpaper

Click on the links below to be taken to each step to build your own DIY Barn Door and DIY Barn Door Track That Won’t Break the Bank!

  1. Instructions for Grey Wash Wood Finish 
  2. Pipe Fitting Handle Instructions 
  3. Sliding Barn Door Plans 

Or click here for our original Upcycled Barn Door Reveal.

 

BARN DOOR COLLAGE 3

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  1. Cindy Brooker says

    Your barn door is beautiful! I am looking at by pass barn doors, hardware alone starts at $630 on some sites, any suggestions on how to build them?

    • says

      Unfortunately the way we’ve built it it’s not a privacy door and it does not lock. You could make a few changes and make it more private and locking I suppose. :)

    • says

      The whole project cost us less than $200 and all the measurements are in the post. The wood was from heavy duty pallets, so I don’t know what type it was. Hardwood for sure.

  2. says

    I LOVE your blog and wanted to share your awesomeness with my readers. I featured this barn door that makes me swoon on my blog today. I swear, I’ve show this to my husband at least a dozen times – I hope to find the perfect space to mimic your genius!

    Thanks so much for rockin’ the inspiration!

  3. Roberto says

    Fantastic door and wonderful tutorial!
    When you hang the door to the rail, does it swing and need a floor guide to hold it vertically aligned or is it sufficiently balanced?

    Thanks for sharing.

    • says

      A floor guide would be useful, but not necessary. If you have small children who are going to be prone to swinging on it then yes, add a floor rail of some sort!

  4. valerie says

    I love this!! What color paint did you use on your wall behind the door? the wood and your wall color look awesome together!!!

  5. says

    Do you know the scooter wheel size. Im looking on Amazon for wheels, they come in 100mm or 110mm…..looking for metal core wheels…Are yours metal?…Dont want to design and build based on your specs and make the one wrong mistake with wheel size….Inline wheels might be another option, If i only knew the size…..Barn door problems! …..so excited to start this project ……bathroom door here i come and out it goes…



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