Surprisingly Simple Barn Door

Ba-ba-ba. Ba-ba-barn door! (Sung to the tune of “Barbara Ann” by The Beach Boys- side note, I just told my husband that it was supposed to to be to the tune of “Bop-er-am” and he looked  at me like an insane person. I guess I’ve been wrong all these years, and it’s Barbara Ann. I don’t like the song as much anymore. HA!  But, you can see what I mean, right?? 😆

Anyway, who doesn’t love a barn door? Well, the answer is EVERYONE loves a barn door. Not only are they the perfect decor for any space, but they are functional too… And guess what? You can easily make this door for your own home. I am going to give you the step-by-step. You don’t have to have experience with big DIY projects, and minimal tools are required. Let’s get right to it, and impress those guests shall we?

All items needed for this project are-

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      1. Chop Saw (optional, a skill saw will work too)
      2. Skill saw or Miter saw
      3. Liquid Nails
      4. High grit sandpaper (at least 250)
      5. Primer (this is the one I use for everything)
      6. Paint color of choice
      7. Barn Door Hardware Kit 
      8. Barn Door Handle
      9. Wood for door/trim (I have listed my choices below)
      10. Hot husband/neighbor/friend to help you hang it at the end

That’s it! Please don’t go to Home Depot or Lowes, and buy that ridiculously expensive barn door kit. It’s flimsy, and aren’t things just so much more fun when you have made it yourself? So here is the step-by-step.

Step 1- Go to Home Depot. See how easy this already is?? Go to the lumber section and find the nice plywood. Not the rough, yucky plywood. There is an area with cabinet grade, smooth plywood. That is what you want, you don’t have to do much of any sanding with this particular wood. They come in large 4′ x 8′ pieces. I chose the .75″ thickness. This will be your door.

Ask one of the lumber guys to come help you grab one and cut it to the exact size of your door. Have your measurements all written down, to make it easy. I made my door a couple inches bigger on the top and sides , than the actual opening was. Mine was 90″x 38″. Pretty big door.

Next go to the common board area and grab a couple extra long 1″ x 6″ boards, and two 1″ x 4″ boards (these will make the center diagonals). I believe I purchased the pine. This will be used for your trim. The length you get will depend on the size of your  door.

Bring it home and plop your large piece of wood down on a couple sawhorses. In my case, I am using storage bins to hold up the door. I am pretty fancy, so try to keep up. 😉

Always measure your door again, Home Depot’s cut likely wont be exact. It will be straight, but not a perfectly accurate length.

Cut two 1″ x 6″ boards the length of the door for either side.  Then, measure the distance between the two boards at all 3 spots- top, middle, and bottom. Cut the remaining pieces for these spots.

 I lightly sanded all the wood, just to give a smooth surface. This wood is already fairly smooth, but I was going for a more finished look for this project.

Apply liquid nails to each board, and push into place. This stuff is strong, I am not at all concerned about this ever coming loose. I also bought these little clamps at Home Depot, and love them! They hold the wood down tight so it can dry, and for the rest I just put heavy items on top until dry.

This is the trickiest part of the project- cutting the diagonal trim. I chose to only cut one angle at each end of the wood, because I HATE angles. If a project includes cutting angles, I lose my crap at some point. So, if you want a fancier version of the door angles, you’ll have to find another blog post. This girl is all about the easy way. Alrighty?… So.

Lay your 1″ x 4″ board diagonally across one of the squares you created. Put the corner of your board RIGHT AT the corner of the square on both sides, then with a straight edge, mark the line to follow the board underneath. That is where you will make your cut. (see below)

I used a skill saw to cut these angles, which was a little tricky because its such a small cut. But, it worked. The chop saw won’t be able to follow the angle exactly.

Apply liquid nails and press down until dry. I then went all around the trim with this Wood Filler that I had in the garage already, but I recommend it because it really smoothed out and filled in any small gaps or cracks in the wood.

Apply one coat of your primer, and one coat of your paint. I chose to use white, and actually just ended up using my left over paint from our kitchen cabinets. So, that saved money too! The color is Oxford White by Benjamin Moore. I always recommend the Benjamin Moore Advance Line for any wood painting project, because it’s self-leveling, really thick, and always looks great. (The door is wet in this photo, so you can still see paint lines)

Once dry, follow carefully the instructions that come with your door hardware to hang. I was very happy with the one I purchased, it was nice and solid and the price was like 40 bucks! Can’t beat that.  I also bought this handle. There are a lot of handle options depending on the style you are going for. I just wanted simple and black. So this worked and it was also affordable! (I have an Amazon Prime obsession.. But I swear, I looked other places, too!)

The door is so pretty (which is why I of course, wanted one), and it blocks any light from our bathroom (which is why my husband, of course, loves it too). Oh and look, here he is, helping me hang this very heavy door up!

Have fun and let me know what questions you may have!

Happy ba-ba-ba-ba-ba-barn door making. 😉😂




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