A sliding barn door is the solution for small spaces, eliminating the need for a swinging door. DIYing one is cost-effective and customizable. With the right barn door hardware, installation is simple, adding both function and style to any space.
Materials:
- One large piece of plywood
- Seven 7 ft long 3×1 boards
- Two 7ft long 1×1 boards
- Barn door hardware kit
- Table saw
- Air nailer
- Glass
- Glass cutter
- Jig saw
- Drill
Step 1: Cut, Frame, and Secure the Wood
Start by cutting the plywood to your desired size using a table saw. Then, cut four 3-inch wide, 1-inch thick boards to match the plywood’s length—these will frame the door on both sides.
Set the boards in place to ensure the correct fit. Then, apply a line of wood glue where the boards will lay, press them down for a few seconds, and secure them using an air nailer for added stability. This forms the main structure of the barn door.
Step 2: Measure and Cut the Glass
Cutting glass can be tricky, but with the right tools, it’s manageable. Start by using a whiteboard marker to draw your cut line on the glass, ensuring accuracy. Apply a thin layer of tool oil over the line to help the cutter glide smoothly.
Use a glass cutter to score along the marked line, applying firm pressure to create a clean indentation. For the best results, use a tile cutter press to snap the glass cleanly. If you don’t have one, you can also break it manually by positioning one edge off a counter and pressing down carefully.
Step 3: Cut the Window Opening and Build the Frame
With the glass cut, use it as a template to mark and cut out the window opening on the door. Using a jigsaw, carefully follow the drawn lines while keeping the surface secure to prevent slipping. After cutting, sand the edges smooth to ensure a clean fit for the glass.
To secure the glass, build a frame using 1-inch by 1-inch boards. Measure and cut them to match the length of the glass. Then, create a shallow groove in each board using a table saw with a lowered blade—just enough to hold the glass without cutting through the board. This will allow the glass to sit snugly within the frame for added durability.
Step 4: Paint the Window Frame
Before installing the glass, paint the window frame boards to avoid the hassle of taping off the glass later
Step 5: Attach the Window Support Boards and Secure the Glass
With the window opening and glass ready, attach the support boards above and below the window on both sides of the door. These will hold the window frame in place. Measure, cut, and secure them using wood glue and nails.
Once secured, wedge the glass into the frame—there’s no need for additional nails since the snug fit holds everything together. To prevent vibrations from breaking the glass, place a folded towel underneath and another on top before nailing. Then, use an air nailer to secure the window frame by nailing it into the outer frame, ensuring a solid and stable hold.
Step 6: Drill Holes for the Sliding Door Hardware
With the door assembled, it’s time to prepare for the sliding hardware installation. Following the instructions from the hardware kit, measure and mark the drill points carefully.
For this setup:
- Measure 150mm in from the edge.
- Drill one hole 40mm down and the other 90mm down.
Double-check all measurements before drilling, as these holes will support the entire door. Ensure they align properly with the hardware brackets for a secure and smooth slide.
Step 7: Paint the Door
With the barn door built, apply two coats of paint on both sides. Avoid excess paint to prevent drips, especially around the details.
Step 8: Install the Wall-Mounted Support Board
Since the metal sliding track may not align with the wall studs, install a support board first to ensure a secure mount.
- Cut and paint a sturdy board to match the door.
- Use a stud finder to locate and mark the studs.
- Position the board 100mm from the bottom hole of the door hardware, as per instructions.
- Check alignment with a level before screwing it securely into the studs.
Step 9: Install the Sliding Track
With the support board in place, mount the metal sliding track:
- Mark where the pre-drilled holes in the track align on the board.
- Drill holes into both the board and wall.
- Place spacers over each hole.
- With help, hold the metal bar steady and align it with the spacers.
- Secure the track by screwing it into the spacers and board.
The metal track should sit about 1 inch from the wall, allowing the door to slide freely.
Step 10: Install the Sliding Rollers and Hang the Door
With the metal track installed, attach the sliding rollers to the barn door:
- Position the rollers over the pre-drilled holes on the door.
- Secure them using the provided screws, ensuring a snug fit.
- Check alignment to ensure smooth sliding.
Once the rollers are attached, it’s time to hang the door:
- Lift the door and place the rollers onto the metal bar.
- Carefully let go and check if it holds securely.
- Move the door back and forth to test functionality.
Install the door stoppers (provided with the hardware) at both ends of the track. Adjust them as needed to prevent the door from sliding too far.
A sliding barn door adds style and function, but proper planning is key. Invest in quality hardware, ensure enough wall space, secure structural support, and choose the right handles and latches for smooth operation. Done right, it’s a space-saving, stylish upgrade for any home.
