How to Build a Large Barn Door

Building a large barn door requires the use of heavier materials including 4 by 4 boards, and larger 6 x 1 boards. It's a Texas sized door that has to hold together under some pretty tough conditions which include opening and closing several times a day, strong winds, bangs and bumps from animals and farm equipment, plus a whole lot more.

Things You'll Need

• 4 x 4 boards
• 6 x 1 planks
• 2-inch nails or wood screws
• 3-inch nails
• 6-inch nails
• Hammer
• Miter saw or hand-held saw

Instructions

1. Cut your 4 by 4 beams to size, then lay them out in the shape of your barn door.

2. Attach the beams together using galvanized metal braces, with 3-inch long nails. Drive one or two 6-inch nails into the beams for extra strength.

3. Cut a cross section 4 by 4 beam and install it in the dead center in the frame. Attach this using nails and metal braces.

4. Measure the distance from the bottom corner to the opposite corner just under the center brace, then cut a 4 by 4 beam to this length. Angle cut the corners at 45-degrees so the brace lays right inside the frame, and then attach the brace using the 6-inch nails. Repeat this step for both sections of the frame.

5. Cut enough 6 by 1 boards to cover the frame. Lay them on the frame then attach them to the barn door frame using 2-inch wood screws or 2-inch nails, galvanized.

6. Add trim to the barn door by cutting the 6 by 1 boards in half, then attaching strips along the bottom, sides and across the center. Now you have a really strong, attractive looking large barn door.

Resources

• Large barn doors
• Ready-made barns