How to Build Country Style Farm/Barn Doors

Make a country-style farm or barn door from reclaimed wood to accentuate the rustic style.

A country-style farm or barn door is a classic option for enclosing a garage, shed, bulkhead or even a modern loft-style apartment in the middle of the city. The rustic design of the door creates simple lines and traditional beauty. Select reclaimed boards for your door to give it additional character. This door is designed to be a standard 36-by-80 inches, but you can modify the dimensions to suit your specific door opening.

Things You'll Need

• Wire brush
• 6 reclaimed boards, 1-by-6-inch, 80 inches long
• 2 reclaimed boards, 1-by-8-inch, 36 inches long
• 1 reclaimed board, 1-by-12-inch, 36 inches long
• Tape measure
• Box, wood screws 1-1/2-inch, decorative head
• Screw gun
• Spray lacquer
• Sliding barn door track set with screws

Instructions

1. Brush all the reclaimed boards lightly with the wire brush to remove any loose debris or dirt on the surfaces. Brush in the same direction as the wood grain to avoid scratching the wood.

2. Lay the six 1-by-6-by-80-inch reclaimed boards on a work surface. Orient the boards vertically and butt the 80-inch edges together to form a rectangular panel that measures 36-by-80 inches.

3. Position one 1-by-8-by-36-inch board flat and oriented horizontally across the top ends of the boards. The outside edge of the 1-by-8-by-36-inch board should be flat with the ends of the vertical boards. Lay the second 1-by-8-by-36-inch board horizontally across the center of the length of the vertical boards.

4. Place the 1-by-12-by-36-inch board flat and oriented horizontally across the bottom of the vertical boards. The outside edge of the board should be flush with the bottom ends of the vertical boards.

5. Measure the 36-by-80-inch rectangular layout from corner to corner with a tape measure. Adjust the boards until both corner to corner measurements are equal. This is how you will ensure that the door is square.

6. Fasten the horizontal boards from steps 3 and 4 to the vertical boards by driving four evenly spaced wood screws through the boards into each vertical board at each intersection using a screw gun.

7. Spray the door assembly with two coats of spray lacquer. Allow the first coat to dry at least four hours. Allow the second coat to dry 24 hours before handling.

8. Fit the track wheels of the sliding barn door track set on the top edge of the door assembly. Position one track wheel 3 inches in from each side edge. Fasten the track wheel to the door assembly with the screws included in the set and a screw gun.

9. Align the sliding barn door track part of the set above the door opening. Fasten the track to the door frame above the door opening with the screws included in the set and a screw gun. Lift the door up and lower the wheels onto the track.

Tips & Warnings

• Instead of using reclaimed wood, you could use new wood and paint it a bold color to act as an accent.

• Wear eye protection when woodworking to avoid an eye injury.

References

• "House Tweaking"; DIY Sliding Barn Door: Part I; Dana R. Miller; Feb. 10, 2011
• "Mother Earth News"; The Handmade Door; Jeff Taylor; November/December 1990

Resources

• Builder Bill; Batten Doors, Ledged and Braced Doors; Bill Bradley
• Historic Doors: Glossary -- Batten Door