DIY Custom Barn Door

I am so excited about today’s project! This DIY Custom Barn Door has been on my list of to-do’s since I moved in. I always thought it would look beautiful in place of my laundry room door and I’ve also wanted it for function. My laundry room is long and narrow so I’ve utilized the side wall for hanging bags and backpacks. When there are bags hanging on the wall it won’t allow the laundry room door to open all the way so my plan has always been to replace it with a Barn Door.

I finally got the itch to build it and I couldn’t be happier! I wish I did it years ago! As always we have the how-to video and the free printable plans for you to build your own!

You can watch how easy this was to build, below!

You can jump to the FREE printable plans here!

How to Build a DIY Custom Barn Door

Tools:

• Miter Saw
• Drill
• Kreg Jig
• Brad Nailer
• Stapler (optional)
• Pin Nailer (optional)
• Table Saw (optional)
• Face Clamp (optional)
• Circular Saw (optional)

Supplies:

• 1 – 1x6x10 Common Board
• 1 – 1x6x8 Common Board
• 3 – 1x4x8 Common Board
• 5 – 1/4″x4x8 Bender Board
• 4 – 1/2″x4x4 Poplar
• 2 – 1/4″x48″x96″ Hardwood Plywood
• 1 1/4″ Pocket Hole Screws
• 1 1/4″ Brad Nails
• 5/8″ Pin Nails
• 5/8″ Staples
• Wood Glue
• Glue Bot
• Barn Door Hardware
• Barn Door Pull
• Floor Guide

Building the Frame

Step 1: I cut the frame pieces to size and used my Kreg Jig to drill 3/4″ pocket holes at each end of the long boards.

• You can find our favorite Kreg Jig Model here!

Attach them to the short boards with 1 1/4″ pocket hole screws and wood glue.

Step 2: Cut the plywood sheets to size and attach them to the frame with 5/8″ staples and wood glue.

• You can find the BEST wood glue dispenser here!

Step 3: Cut the top and bottom trim pieces to size. Attach them to the top and bottom of the barn door frame with 1 1/4″ brad nails. The bottom of the trim should be flush with the bottom of the frame.

Step 4: Cut the side trim pieces to to size and attach them to the sides of the barn door with 1 1/4″ brad nails and wood glue.

Adding the Trim

Step 1: Cut the top and bottom, front trim. Attach it to the top and bottom of the plywood with 5/8″ pin nails and wood glue.

Step 2: Cut the vertical bender boards to size. Attach them to the sides of the plywood with 5/8″ pin nails and wood glue.

Step 3: Cut the squares to size, center them on the plywood according to the sketch and attach them to the plywood with 5/8″ pin nails and wood glue.

Step 4: Cut the side trim pieces for the squares. Attach them on the outside of the squares with 5/8″ pin nails and wood glue.

Step 5: Cut the top and bottom trim pieces to size and attach them the same way.

Step 6: Cut the final trim pieces to size. Center them on the squares according to the sketch and attach them the same way.

Step 7: Cut the wheel blocks to size and attach them to the top corners of the barn door with 1 1/4″ brad nails and wood glue.

Step 8: Before hanging the barn door, I filled my nail holes sanded it down and added a finish. I chose Urbane Bronze by Sherwin Williams for the finish.

Hanging the Barn Door

Step 9: I took my laundry door off the hinges and attach a pre-primed 1×6 over the door. This will give your barn door track a solid piece to attach to. I used my level to mark where to attach the track.

I’m so happy with the way my barn door turned out. It was so simple, inexpensive and it’s the most perfect combination of form and function! It completely transformed my kitchen and gave it a unique update!

Make sure to share your builds with us on social media and use #shanty2chic so we can share them too!

Happy Building!