See project diagram for lumber required.
What You Need for This Project
Tools
Items may be Special Order in some stores. Product costs, availability, and item numbers may vary online or by market. Paint colours may vary slightly from those shown. Availability varies by market for lumber species and sizes.
Resources
Cut List
| Part | Name | Thickness | Width | Length | Material |
Pieces |
| A | Stiles | 3/4 inch | 3 1/2 in. | 84 in. | P | 2 |
| B | Top/Bottom Rails | 3/4 in. | 5 1/2 in. | 29 in. | P | 2 |
| C | Crossbar | 3/4 in. | 3 1/2 in. | Cut to fit | P | 1 |
| D | Edging | 3/4 in. | 1 1/2 in. | 84 in. | P | 2 |
| E | Siding | 3/4 in. | 7 1/8 in. | 84 in. | CS | 3 |
| F | Siding Filler Strips | 3/4 in. | Cut to fit | 84 in. | CS | 2 |
Materials: P — pine, CS — Pine Car Siding
A Sliding Barn Door is Easy to Build
Once you know how big the door needs to be, adjust the length of the stiles and the top/bottom rails to the desired lengths. The crossbar is cut to fit the actual door. The car siding is designed to have one board centered in the door panel and then fit the boards toward each side, all cut to fit the door as it is built.
Make a Frame
Cut the Stiles & Rails
Cut the stiles (A) and top/bottom rails (B) to size. Sand the parts with 120-grit and 180-grit sandpaper. (A random-orbit sander makes quick work of this.)
See "Drawing 1: Frame Assembly" in Sliding Barn Door Project Diagram for details.
Drill Pocket Holes
At the end of the top/bottom rails, drill pocket holes to receive the pocket-hole screws using a pocket-hole jig.
Tip: Drill pocket holes to leave space for the door hardware. On the top rail, drill two closely spaced holes near the bottom edge of the board.
On the bottom rail, drill two holes about 1 inch from both the top and bottom edge of the board.
Align the Rails
Align the top/bottom rails (B) with the ends of the stiles (A). Add glue and drive the pocket-hole screws to make the frame.
See "Drawing 1: Frame Assembly" in Sliding Barn Door Project Diagram for details.
Mark the Crossbar
Draw a centered line down the board for the crossbar (C). Slip it under the frame and align the mark with the inside corner of the frame.
At both ends, trace the shape of the frame on the crossbar.
See "Drawing 1: Frame Assembly" in Sliding Barn Door Project Diagram for details.
Drill More Pocket Holes
Clamp a pocket-hole jig to the stile near the corner and drill a pocket hole on the back face of the frame.
Repeat on the diagonally opposite end.
Cut & Attach the Crossbar
Using a jigsaw, cut the crossbar and sand the edges smooth. The bar does not have to be a perfect fit — ease the edges where it meets the frame to create a rustic look that helps hide imperfections in the jigsaw cut.
Glue and screw the crossbar to the stiles.
Add the Siding
Cut Siding Boards
Cut two 1 in. by 2 in. boards to match the height of the door for the edging (D). Glue the edging to the sides of the door with the outside edge flush with the outside edge of the frame stiles.
The edging creates a smooth edge along the door and conceals the edges of the siding boards.
See "Drawing 2: Siding" in Sliding Barn Door Project Diagram for details.
Cut Car-Siding Boards
Cut car-siding boards to match the height of the door for the siding (E), and the siding filler strips (F).
Measure the distance between the edging and subtract 1/4 inch from the overall width of the siding; this will allow the siding to install easier.
See "Drawing 2: Siding" in Sliding Barn Door Project Diagram for details.
Centre the Siding Board Pattern
To centre the siding board pattern in the door opening, combine the widths of the five siding boards and mark equal amounts to be trimmed from the two siding filler strips (F).
See "Drawing 2: Siding" in Sliding Barn Door Project Diagram for details.
Attach the Siding Boards
Assemble the siding boards between the edging and secure them to the frame with 1 1/4 in. drywall screws.
Attach the Siding Boards to the Crossbar
Use a scrap and mark a diagonal across the door going in the same angle direction as the crossbar. Use the line to position screws and drive to secure the siding boards to the crossbar.
Mount the Hardware
Mark & Cut the Hardware Notches
Tape around the area where you’ll notch the top of the door to receive the hardware. Mark out and cut the notches with a jigsaw.
See "Drawing 3: Roller Attachment" in Sliding Barn Door Project Diagram for details.
Attach the Roller Hardware
Position the roller bracket on the door, use the holes in the hanger to locate and drill holes for the bolts. Attach the hardware pushing the head of the bolts from the backside, and use the nuts and washers on the front.
The rounded heads of the bolts protrude less on the backside, preventing them from scraping the wall.
See "Drawing 3: Roller Attachment" in Sliding Barn Door Project Diagram for details.
Stain or Paint the Door
Remove the hardware and sand any rough edges. If you are going to paint, apply a stain blocking primer prior to applying paint to seal any of the knots in the pine.
Finish with the paint of your choice.
How To Terms
Jump to:
- Cut the Stiles & Rails
- Drill Pocket Holes
- Align the Rails
- Mark the Crossbar
- Drill More Pocket Holes
- Cut & Attach the Crossbar
- Cut Siding Boards
- Cut Car-Siding Boards
- Centre the Siding Board Pattern
- Attach the Siding Boards
- Attach the Siding Boards to the Crossbar
- Mark & Cut the Hardware Notches
- Attach the Roller Hardware
- Stain or Paint the Door
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