DIYSlidingBarnDoor DIYPETELLC

DIY Sliding Barn Door
Thank you for downloading the DIY Sliding Barn Door Guide!
The complete Youtube video and project tutorial photos to go along with this guide can be
found at http://www.diypete.com/barndoor - You will need to make changes to the plans
to fit your door opening. Good luck with the project and have fun building it! Please post
project photos on the Facebook page at www.facebook.com/DIYPROJECTSWITHPETE or
elsewhere tagged with #DIYPETE
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http://www.diypete.com/barndoor - Copyright 2016 - DIY PETE, LLC
Tools Needed
*Please note - By using these links to purchase tools you are helping support
DIYPete.com.
Miter Saw Id recommend a 12 inch miter saw

Table Saw OR Circular Saw
Drill
Brad Nailer
Angle Grinder with Flap Disc
Drill Press - Highly recommended and it will make the project 10 times easier
Reciprocating Saw - with metal blade
Metal Cut off Saw - optional
Impact Driver (Optional)
Orbital Sander Ryobi makes a nice one.
Wood Chisel
Socket Wrench Set
Drill bit set with various sizes
Stud Finder
5/8 inch drill bit
Carpenters Square
Clamps
Tape measure, straight edge, pencil, Level
Wall paint for spacer board/spacers
Paint Brush
Respirator mask
Dust Mask
Respirator/dust mask, eye, ear, and hand protection
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Shopping List:
Project grand total: $268.07

*You'll want to go to a local steel supplier in your area for the metal. Home Depot and
Lowe's doesn't carry anything much longer then 6 foot pieces and they are also more
expensive.
* Cost does not include tools, bits, or blades
Total Cost Hardware/Steel: $130.96
Steel for Door Wrap - Qty 3: 3/16" x 2 inch x 10 feet long steel flat bar -
$9.39/piece $28.17
Steel for Rail and Door Mounts - Qty 1: 1/4" x 2 inch x 10 feet long steel flat bar:
$11.02
1 1/2 inch Angle iron for door stops and bottom track: $9.18
Flush Cabinet Pull: $1.41
Pipe Cabinet Pull Handle: $9.98
2 1/2 inch screws for Handle: $1.18
QTY 2: 3 3/4 inch Diameter 5/8" bore V idler pulley wheels $18/ wheel + $7
Shipping - $43.00
Hardware Bolts, Nuts, Lag bolts, and Washers for Hardware: $27.02
For the hardware you'll need:
Add Steel Wrap
Qty: 18 - 1 1/2" long screws to attach flat bar to wood door
Mount Door Hardware

Qty:4 - 1/2 inch x 3 inch long hex bolts
Qty:4 - 1/2 inch washers
Qty:4 - 1/2 inch nuts
Hardware to Attach Wheels

Qty:2 - 5/8 inch x 1 1/2 inch long hex bolts
Qty:2 - 5/8 inch washers
Qty:8 - 16 mm washers
Qty:2 - 5/8 inch nuts
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Rail Hardware
Qty: 6 - 3/8 inch lag bolts ( 5 inches long ) and 6 washers

Qty: 2 - 5/16" by 1 inch long hex bolt for angle iron stopper
Qty: 2 - 5/16" washers
Qty: 2 - 5/16" nuts
Track / Channel Hardware

Qty: 4 - 1 1/2" long screws to attach angle iron channel/track to floor and 4 washers
Total Cost Wood: $103.66

QTY 32: 1x6x5 long Fence Pickets - $2.15/board - $68.80
QTY 1: 22/32 sheet Plywood or OSB: $22.00
QTY 1: 1 1/4 inch Dowel for Spacers: $4.52
QTY 1: 1x4x8 Spacer Board: $8.34
Additional Supplies: $33.45

Minwax Waterbased brush on sealer (satin) - $9.98
Matte Spray Sealer for Metal: $3.54
Construction Adhesive QTY: 3 @$1.77/can $5.31
Dark Metallic Colored Spray Paint: $4.35
Paint Brush: $2.25
1 1/4" 18 gauge brad nails: $8.02
2 Felt pads for stoppers $2.10
For those interested in buying the hardware you'll be able to find all kinds of options on
Amazon.com and other sites. Please do your research to decide what hardware will fit
your exact door. Here is an example of a heavy duty sliding barn door hardware kit and
rail.
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Cut a sheet of plywood down to size using
Measure the door opening. I made my door 4 inches wider than the opening and 2 inches
taller. This enabled it to overlap the wall 2 inches on each side. You may want to make it
wider to cover door trim if you have it. We will wrap the door with 3/16 x 2 inch steel flat
bar, so the overall width of the wood should be of an inch less than the final width of the
door. Cut the door down to size using a circular saw.
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Cut Fence Pickets
Use a miter saw to cut the fence pickets. They should be the same width as the plywood. I
cut mine to 37 for my door. Use construction adhesive and 1 brad nails to attach
them. Complete the first side, flip the door, then add the pickets on the second side. You will
most likely need to rip the last board in width so it fits perfectly on the plywood.
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The plywood will be sandwiched between pickets on each side. The total thickness will be
almost 2 inches exactly. The steel is 2 inches thick so it will match up very closely.
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Attach Steel
Attach the steel around all four sides, one side at a time. Determine hole locations for
drilling through the metal so youll be able to use screws to attach it to the wood door. I
spaced the holes about every 10 inches apart and made sure a hole was about an inch or so
from each end. I did three holes on the short horizontal pieces and six holes on the long
vertical pieces. Use a drill press to make the holes. The horizontal flat bars should be the
same width as the pickets. The long pieces will overlap the edges of the horizontal pieces.
Use construction adhesive and 1 inch screws to attach the metal.
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Create Door Hanging Hardware
Make the door hanging hardware out of inch by 2 inch steel. I cut the steel to 16 inches in
length. 9 inches of the metal will hang on the wood and 7 inches will be above the wood
and contain the wheel. Measure down from the top 3 inches and drill a hole which will
be used to attach the wheel. From the bottom measure up 2 inches and 7 inches for the
two holes that are inch diameter.
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Attach Hangers
Attach the hangers to the door. I used inch hex bolts that were 3 inches long. Put a
washer on the front side and back side. Attach the wheel with a inch by 1 inch hex bolt.
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Up close Diagram of Wheel Hardware
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Once the door hangers are completed and attached youll want to work on the rail and
spacers. The rail needs to be at least a few more inches in width than twice the width of the
the door. Holes will need to be drilled in the rail that match up with the studs in the wall.
(Typically 16 inches on center). My metal rail was a little wider than normal since I needed
to clear a light switch with the door when open. Id recommend cutting a 1x4 board down
to 3 inches in width and an inch or 2 more in length then the metal rail. This is used as a
spacer. In addition to the spacer board youll need 1 inch long spacers made out of a 1
inch dowel. The spacers keep the door away from the wall so it will slide back and forth.
Make 1 inch long stoppers out of angle iron and attach each with a 5/16 bolt, washer, and
nut. Buy or make your own track / channel using angle iron. For more details please check
out the tutorial at www.diypete.com/barndoor and watch the Youtube tutorial I created.
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Enjoy
Youve done the work, now enjoy your new Sliding Barn Door! Modify your build as needed
and share this project with your friends. Thanks for following along and be sure to check
out the free blog post and video tutorial at http://www.diypete.com/barndoor.
Cheers!
Thanks so much for checking out the DIY Patio Chair plans. Id love to hear how your
project goes! Please post photos on Facebook at www.facebook.com/diyprojectswithpete
and subscribe to my Youtube channel at www.youtube.com/diyprojectswithpete.
Cheers from Montana,
* Please refer to the post at http://www.diypete.com/barndoor and check out the video
tutorial for more information, instructions, and tips.
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DIY Sliding Barn Door

Miter Saw Id recommend a 12 inch miter saw

Project grand total: $268.07

Total Cost Hardware/Steel: $130.96

For the hardware you'll need:

Add Steel Wrap

Qty: 18 - 1 1/2" long screws to attach flat bar to wood door

Mount Door Hardware

Hardware to Attach Wheels

Qty: 6 - 3/8 inch lag bolts ( 5 inches long ) and 6 washers

Track / Channel Hardware

Total Cost Wood: $103.66

Additional Supplies: $33.45

Cheers from Montana,

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