Home Improvement Project: Barn Door

Tyler and I have just been over the moon when it comes to this whole “homeowner” thing. Of course, there have been some stressful moments along the way (over-flowing toilets and all), but I think we both are still very pleased with our decision to take the leap!

I love it because we have SO MUCH ROOM! (Or at least, compared to what we did have!) And I love it because it’s ours, all ours! Tyler loves the space also, but more than anything I think he loves being able to put our own touches on the house. We joked after we moved in, that Tyler, who is an electrician by trade, also took on the roles of locksmith, plumber, gardener, and a whole bunch more! Well, now he can officially add “wood-worker” to his list! (He already possessed that title after he made a BEAUTIFUL cedar chest in high school that traveled with us to Oklahoma City, and now to our home in Denver.)

I present to you… our one-of-a-kind Barn Door!

The Finished Product:

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Ta-Da! The Finished Product!

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Door Closed.

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View from the inside!

We decided almost immediately, we wanted our “design/decorating theme” to be “cottage/farm-house.” We live in a quaint, 3-bedroom/2-bathroom ranch, so we thought it was perfect! We also decided almost immediately that the master bathroom door was going to have to go.

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Bathroom Door (outside) – Before.

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Bathroom Door (inside) – Before

The way the door swings just makes the nook for the toilet seem awkward. So, we agreed that a Barn Door feature would be the perfect touch to tie in the cedar chest, and solve our awkward door problem!

So here’s how we did it!

Before anything, Tyler drew up these plans for our Barn Door concept!

Pretty, huh? So this was our jumping off point! Next, it was time to put our design into action!

We started by making a layer with 1’X8′ tongue & groove cedar planks that we picked up at Home Depot. They took some “finagling” (and wood glue), but we made them work! After tons of sanding with 80 grit, 150 grit, & 220 grit with the electric sander, & 400 grit & 800 grit hand-sanding – including wet sanding – the wood was as smooth as butter!


Next, we installed the Barn Door hardware (Umax 6.6 ft Sliding Barn Wood Door Horseshoe Sliding Track Hardware Kit from Amazon.com), to give us an idea of how tall and wide the door needed to/could be.


After cutting the door down to size, we got some 1’X8′ cedar planks (without tongue & groove). These created the border (tops, sides, & middle) and “½ X” design feature in the center. This, again, involved sanding (as done above… Tyler is an avid sander!), and trimming. We attached these with wood glue and screws. Using a “plug cutter,” we were able to “hide the evidence” of the screws, but it also gave us more “peace-of-mind” that the two sections would be secure.

Before the slats were attached to the Tongue & Groove flat.

In progress… a late night work session!

After many more hours of sanding, sanding, and more sanding, it was then time to stain! We decided to go with a natural stain so that we could bring out the character of the cedar. We pre-stained (then sanded), stained (then minimal sanding), and then applied 3-coats of top coat to give it that extra shine (and to protect the soft cedar wood)!

Price Check
(all costs estimated)

Materials:

  • Tongue & Groove Cedar Planks (7 – 1X6) – $100
  • Cedar Planks for “Design” (4 – 1X6) – $65
  • Elmer’s Wood Glue (2 bottles) – $10
  • Wood Putty (used to fill various holes/cracks along the way) – $5
  • Sand Paper – $8
  • Paint Brush – $12
  • Screws (60) – $4
  • Minewax Natural Wood Finish – $8
  • Polyurethane  – $13
  • U-Max 6.6 Ft Sliding Boor Door Hardware Kit – $50 (Amazon Prime)
  • Adjustable Channel Wall Mount (Door Guide) – $35 (Amazon Prime)
  • Door Handle – $23 (Amazon Prime)
  • Materials Total – $323

Tools:

  • Saw Horses (4… 2 from Home Depot, 2 from Amazon Prime) – $90
  • Circular Saw – $50
  • Electric Sander – $85
  • Clamps (6 – Various Sizes) – $83
  • Plug Cutter Set (of 3) – $10
  • 4′ Level – $15
  • Stud Finder – $35
  • Tools Total – $368 (some tools previously owned)

PROJECT TOTAL – $691

All in all, I think we are both VERY happy with how this turned out! Before going on this venture of making our own Barn Door, we researched and found pre-made or custom-made Barn Doors that were upwards of $2,000! YIKES! We knew we couldn’t (and didn’t want) to spend that kind of money! There were some that were less expensive, but we also knew it was important for us to be able to make it our own – a custom, one-of-a-kind barn door – something we would both love to look at every day, and feel proud of the work that went into it! This is something we hope to cherish for many years to come, in this home, and any future homes we may have! This was a fun project that allowed us to work together as a team, and gave us a beautiful new design element for our first home! And if you ever come to visit, we’ll be sure to talk your ear off about Our Barn Door! 🙂

Until Next Time,

~*~ Megan ~*~