Spend Less than $250 to Build & Hang Your Own Barn Door from Scratch
Total Cost??? Under $250! What?!
Barn doors are all the rage right now. People love this trend and it’s easy to see why! Barn doors come in endless styles and sizes. They transform something as mundane as a door into a fabulous feature, and people (myself included) find their smooth glide mesmerizing!
These are the first little guys we ever built!
The more popular barn doors become, the more everyone is getting in on the action! There are places like Rustica Hardware that specialize in making custom barn doors for any space, but they are pricey. Now, even Home Depot has its own line of barn doors which are somewhat more affordable.
However, today we’re going to show you how to make and hang your own barn door for less than half of even Home Depot’s price. The greatest thing about making your own barn door is that your options are endless. You can paint them, stain them, and construct any kind of center brace you want. A few months ago, we renovated my parents laundry room. It was a quick project with a small budget but had a major impact on how their day to day life functions.
We have a big family and just this week my parents added to it by adopting my two new sisters. This brings the grand total to 9 of us ranging in age from 40 to 13…crazy right?!
Anyway, my mom mentioned wanting a barn door for the laundry room and though Wendy and I have made several barn doors for clients, we’d never hung one…until now. It’s really not as hard as I thought it was going to be and today I’m giving you the inside scoop!
We made these custom Z-Brace Barn Doors for a client’s pantry. These are stained, and we had a contractor hang them.
As I mentioned above, these were our first barn doors! We made these and had a contractor install them in a client’s basement to separate the ‘kid area’ from the ‘adult area.’ These are painted.
I will tell you right off the bat that the most expensive part of this barn door build was the barn door hardware. I’ve seen people make their own hardware but we opted to purchase an entire set from Home Depot to save time since we were making our door from scratch. The barn door hardware set we bought is called the Everbilt Dark Oil-Rubbed Bronze Sliding Door Hardware Kit and cost $159.99. The set comes in oil-rubbed bronze and satin which looks like a brushed nickel silver. These used to cost $119.99 but have been rising in price probably due to their popularity.
You can see the hardware set comes with every piece you need.
These sets are carried in stock and in the store so there’s no waiting! You can go get it and get started today 🙂 They accommodate doors up to 36 inches wide. However, they sell an adapter piece for an additional $10 allowing you to add another door up 36 inches or make a single door as wide as 72 inches.
Everbilt Oil Rubbed Bronze Connecting Adapter for Flat Rail
In both pics above, we used the adapter piece enabling us to hang two doors.
Let’s get to the Laundry Room Barn Door!
We started our project by first making the door. A while ago we discovered sheathing (sounds like shee-thing) when we were looking to build our first barn door. It’s found at Home Depot or Lowes in the lumber section and is usually used for siding on sheds and other types of exterior. However, I like it for a barn door because it automatically gave us a rustic feel and the visual interest I was looking for. Our door was going to be 36 inches so we bought one 4ft by 8ft sheet of sheathing. We had it cut down to 38 inches (width-wise) at the store so it could be loaded into the car (SUV suggested).
This is what paneled sheathing looks like!
I’m guessing the sheathing-makers never intended sheathing to be used as barn door material (leave it to us DIYers!) so every piece is sold with a small tongue making each piece easy to connect to another. I say this because you’ll need to cut the lip off to make the door even.
See the lip all the way to the right?
One pass with the circular saw—problem solved!
As I said before our door was going to be 36 inches wide and 84 inches tall. We did this because our door opening was 30 inches wide and the standard door height is 80 inches BUT we planned to leave the casing around the door opening in place which added a 3 inch perimeter on each side. When accounting for the casing, our 36″ x 84″ door would completely cover everything which was the look we wanted.
The foundation for the door! Every project, every door, it never gets old! I love the excitement of seeing the vision take place.
With our door cut to the right size, we used an orbital sander and sanded the top and edges for a smooth finish. We started with 150 grit sandpaper, and finished with 220 grit. * To make your life easier for staining or painting, do not skip this step!
We did 2 passes with each sandpaper grit for a total of 4 passes with the sander.
In order to give the door some depth we bought three 1 inch x 4 inch x 8 foot pieces to be placed around the perimeter. While you have the option to miter the corners, we kept it really simple by not mitering and placing a straight center brace in the middle. We made our cuts with a chop saw and used wood glue, finish nails, and clamps to join them together. This ensures that the door will hold up for years to come.
Pieces cut to size! Wood glue on!
Clamps on. We let the door sit like this over night.
Once that was complete, we painted both sides of the door in three coats of Glidden’s Silver Cloud and let it dry. Then we attached the hardware. To figure out the correct measurement, we measured the height of another door knob and attached it at the same level, 36 inches. We chose a simple black handle because it closely resembled the rest of the hardware.
Glidden’s Silver Cloud
Door hardware. We didn’t try to be fancy here, we just picked up a pull from the kitchen cabinetry hardware aisle in Home Depot.
With the door complete, it was time to move on to hanging the sliding bar. The directions that come with the hardware are fairly clear. Before we could hang the sliding bar we needed to hang a ledger to act as the foundation for the sliding bar. We cut a ledger that was about 4 inches larger than the size of the sliding bar. We used a 1″ x 6″ piece for this painting it in a semi-gloss white to match it to the rest of trim and baseboards.
Partially done first coat!
After that, we used a stud finder to find the studs in the wall and marked them. Then we dry fitted the 1×6 on the wall and marked where the studs were. Once the marks were made we pre-drilled holes on the ledger to keep it from cracking.
Finally, we screwed the ledger into the studs. This served as the foundation for the door and ensured that it would be supported over the long haul.
Then we attached the bar by first screwing in the spacers and then placing the stoppers on the end. The stoppers keep the doors from falling off the sliding bar. **Make sure the sliding bar and ledger are level. Otherwise the door will always slide to one side.**
Pre-drilling the holes after locating the studs. Please excuse the background!
Dry-fitting again before screwing in the ledger board.
Ledger board installed!!!
You will have to mark your studs higher up on the wall than your ledger board so you’ll know where to hit the stud with the screw. Once it’s screwed to the wall, use touch-up paint to cover up your marks.
You can see the sliding bar up on the wall. That’s basically it as far as the bar. The only pieces we hadn’t put on in the pic above were the stoppers that go on each end of the bar. They keep the door from sliding off the bar.
Once the ledger and sliding bar were up on the wall, it was time to attach the slide wheel hardware to the top of the door. We marked the holes and pre-drilled them to keep the door from cracking. It’s extremely important to leave enough room between the top of door and sliding bar to ensure a smooth slide. We also suggest leaving a half inch between the bottom of the door and the floor just in case the floor is not level. Try to be as exact as possible when attaching the slide wheels to ensure the smoothest slide possible.
You can see the hardware placed, tightened, and ready to go!
The last step is to hang the door by placing the slide wheels on the sliding bar. There you have it– a new gorgeous barn door that will be an amazing feature for years to come!
Materials for this project break down like this: barn door hardware $160, wood $40, paint $12, and sheathing $30. Grand total $242. That’s less than half the cost of Home Depot’s most inexpensive door! For money, time, and the look, this DIY Barn Door can’t be beat! Tell us what you think in the comments below!