Today I’m sharing ALL the details on our DIY barn door hardware and shiplap door. I actually revealed the door back when I shared my mudroom reveal, but I never shared the details on how I built it. Today I’m giving you the entire lowdown. This entire project, including the door came in well under $100!
First I took some baseboard and attached it around the perimeter using my brad nailer.
Then I took thin plywood and ripped it down into 4.5″ strips and measured the width of the door inside the trim pieces.
Then I attached these pieces to the door using my nailer. Most pieces took 6 nails. I just spaced them with my eye, but they are about a dimes width apart from each other. This is the nailer I used for this project.
When I got to the bottom strip I had to rip that one just a bit wider so that there wasn’t an awkward gap left.
Then I painted it my favorite green: Benjamin Moore Hidden Falls. First I brushed the cracks and then I used a roller to hit the rest.
Then I screwed a 1×4 stain grade board to the wall where the barn door track was going to be mounted. This was to determine and mark where the studs were. Then I took it down and brought it outside.
The important part here was making sure that it was clamped really well to the board. I also used a metal punch to mark the holes before drilling. This helped the drill bit stay in the right place.
Then we used a hacksaw to cut the metal bars down to size that would be attaching the barn door. I’ll explain more in a bit, but we used 1/8″ thick metal, and I wish that I would have used 1/4″ thick instead. This is actually my second time using this method, here is the tutorial I wrote last time.
We also stained the wood board before hanging it back up.
Next I assembled the bar over the wood in the following order, “Wood, 6 standard washers, steel bar, 1 4″, 1/4″ hex lag screw”. Once we had all 4 lag screws attached to the wood with the washer spacers we just mounted it on the wall in the pre-measured spot hitting studs with all 4 screws.
Next we drilled four holes through each 1″ piece of steel. You might notice I drilled a hole too high that I ended up not needing. Then we assembled the wheels by placing the bolt through the steel and then placing 4 standard washers between the steel and wheel, and a nut on the back of it. Then we just mounted it to the door using 4 1″ lag screws. Then the wheels just set onto the track.
One thing that I didn’t think about was how close the wheel comes to hitting the screw. I wish I would have either used a 2″ bar, or put the holes about 1/4″ lower so that the wheel doesn’t come so close to hitting the screws.
The other mistake that I made was that I wish I would have used thicker steel for the brackets. Because I didn’t you can see how the weight of the door sort of bows the steel. Back when I made this same track last time I used thicker steel and didn’t have this issue.
When it was all assembled I added this handle to the barn door. When you open and close the door as long as you use the handle to pull out it doesn’t scrape the trim. I think that with a small guide or wheel on the bottom though it would keep you from having to pull the door out like this.
Hopefully this post inspires you that building your own barn door really isn’t that hard! Honestly, after building the track and then seeing how affordable the hardware has become online, I think I would have been better off just purchasing a track! That way it takes all of the cutting, drilling, and spray painting out of the equation! Even if I purchased a track though, I still would definitely build a shiplap barn door like this over and over again.
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