How to Build Pole Barn Doors

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Pole barn doors can add to your convenience, especially when moving heavy equipment or other large items into your pole barn. There are many types of pole barn doors that you can install or build such as swing doors, sliding doors, overhead doors and more. However, if you wish to build tough, durable pole barn doors, you can do so using laminated veneer lumber (LVL) beams. LVL beams are a popular choice for pole barn doors as they are designed for heavy-duty use, easy to work with and, in the long run, cost-effective. Here's how you can build pole barn doors with LVL material beams.

Things You'll Need

  • 8-foot LVL beams (quantity as desired)
  • Two 1/2-inch or 3/4-inch thick hardwood boards (maple or oak)
  • Miter saw
  • Door hinges
  • Tape measure
  • Hammer
  • 2-inch nails (galvanized type)
  • 2-inch screws (outdoor, wooden type)

Purchase an adequate number of LVL beams to match the specifications of the barn doors you require. Pick up maple or oak hardwood boards, as per quantity needed, along with other relevant items from a lumber and hardware store.

Measure the height and width of your pole barn door space. Take four LVL beams and cut them to half the width of your pole barn door opening. Then take another four LVL beams and cut them to match the height of your pole barn doors, ensuring that you reduce 8 inches from each length to allow for the cross beams' width. Make sure you allow a 2-inch space below each door for easy opening and closing of the doors.

Lay the LVL beams alongside each other and use a metal brace to attach them. This will create the basic box frame for each door.

Use the tape to measure the diagonal that runs across both door frames, specifically from the inside bottom corner to the top (opposite) inside corner. You can now cut the cross brace to the appropriate size. Mark the correct angles at the top and bottom of the cross beam, then use the miter saw to cut it so that it fits perfectly within the frame.

Insert a set of 2-inch nails to connect the cross frame, ensuring that it fits precisely within the frame.

Trim the two 1/2-inch (or 3/4-inch) maple (or oak) hardwood boards to match the length of the cross frame. Make sure that the lengths you cut allow for adequate cover of both pole barn door frames. To do so, use the tape to measure the precise length of both door frames and divide the same by the width of the hardwood board you have purchased.

Set the two boards on top of the frames. Then use 2-inch galvanized, heavy-duty nails to attach each board to the bottom and top of the frames and the cross brace.

Connect the hinges and a handle for both doors using suitable screws, ensuring that they are firmly inserted into the brace.

Varnish or stain your pole barn door boards to give them a glossy, finished look.

Tips & Warnings

  • Use galvanized nails and wood screws of high quality. These are ideal for all-weather conditions.
  • Do not work without wearing protective gear, particularly when using power tools.

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