How to Make a Barn Door

A Dutch barn door serves a functional and decorative purpose.

A Dutch door not only adds rustic charm to a building, it serves a functional purpose as well when installed in a horse barn. The door is comprised of two horizontal halves that open independently, enhancing security when the lower section is closed, and providing fresh air and sunlight into the stall when the top section is opened. Opening both sections also allows you to take your horse or cattle out quicker, without taking the animals through the barn. Although wooden Dutch doors are commercially available, construct your own to customize it to the available space.

Things You'll Need

• Measuring tape
• 2-by-6 inch lumber
• Saw
• 3/4-inch plywood sheet
• Electric drill
• Screwdriver
• 2-inch screws
• 2 heavy-duty hinges
• Bolt latches

Instructions

1. Measure the width and height of the space where you will install the door. Using the measurements as a guide, calculate the required height and width for each door. The Dutch barn door should measure at least 4 feet wide and 7 feet tall. Make the upper door 3 feet tall and the lower door 4 feet tall. Leave 1 1/2- to 2-inch clearances between the two doors, the lower door and ground, and upper door and overhead beams. Make allowances for the hinges and latch when determining the width of the door. Note the measurements.

2. Cut two 2-by-6 inch boards long enough to match the width of the top door using a saw. Place the boards horizontally on the ground, parallel to each other. Space them apart so the distance between them equals the height of the top barn door. Saw two identical 2-by-6 inch boards to fit vertically between both of the horizontal boards to form a frame.

3. Saw a piece of 3/4-inch-thick plywood to match the measurements of the door. Arrange the vertical and horizontal pieces of 2-by-6 inch boards around the outer edges of the plywood sheet. Attach the plywood to the wooden boards using 2-inch galvanized screws.

4. Lay a length of 2-by-6-inch lumber diagonally over the frame you attached to the plywood sheet. Mark the spots over the lumber and saw excess off so it fits snugly inside the frame. The board serves as the door's brace. Attach this board to the plywood sheet using a row of no. 14 screws.

5. Lay another 2-by-6 inch board diagonally over the frame, in the opposite direction to the previous brace. Mark along the ends of this board so you know how much to trim. Mark where this board meets the previous brace so you can saw it into two pieces. Saw both pieces of the board to the required length and attach them to the plywood using no. 14 screws to complete the upper door.

6. Cut four lengths of 2-by-8 inch boards to your desired measurements to form the frame of the second or lower door. Repeat the process of joining the plywood sheet to the frame, and forming braces.

7. Hang both doors to the posts using two hinges on each. Align the doors to open and close properly. Install latches on both doors.

References

• Barn Door Plans: Dutch Barn Door Plans for Your Barn
• Pennsylvania State University; Horse Stall Design; Eileen Wheeler, et al.; 2002
• The University of Tennessee Extension: Horse Plans: Saddlehorse Barn