I have loved farmhouse decor for as long as I can remember. I have also wanted to have a barn door in my home for as long as I can remember. I’m southern after all! I loved barn doors and chippy, old things before the “Fixer Upper” craze, but it wasn’t until becoming totally obsessed with that show that I started to make this “barn door” dream a reality.
We’ve been in our new home for almost a year now. I knew I wanted to eventually do rustic/farm style downstairs in our unfinished basement, but couldn’t wait to add a barn door somewhere so I started searching for the perfect space. The Laundry room on our first level seemed to scream PICK ME, so I designed my idea up on a scratch piece of paper and headed with my hubs to Home Depot for the required supplies. Luckily he’s always up for a DIY project on a beautiful weekend. Just turn on a little Chicago’s Greatest Hits, fill up a cup with a fresh Diet Coke and he’s good to go.
First we had to determine the width of the door and how much we wanted the barn door to cover. THAT IS ESSENTIAL. You can add a barn door anywhere, but if the size doesn’t cover the existing door frame it’s gonna look like trash. Just saying! So measure that up. Our door frame needs ended up being 36″ wide x 72″ tall.
Then we ordered the track system from Amazon. It was here (thanks to our Prime account) within 3 days. Here’s that link if you’re interested in ordering that:
1. Next we drove to HOME DEPOT for supplies. We bought 7 – tongue and groove pine boards, 5-1x4x8 Pine wood pieces for the side, the X, the center piece, and the wall railing piece which I’ll explain in step #8. Then we bought 1-1x6x8 for the top and bottom piece. I wanted a thicker board for the top and bottom. My design element of course. We also bought some Rust-oleum stain in KONA color, Gorilla glue, and finishing nails for our air compression nail gun. Kona is my favorite color stain. If you aren’t sure what color you’d like use a small cut of the pine and stain before you commit so you can see what it will look like. Tip of the day. I did this and I’m glad I did or I would have had a reddish brown which I did not want. Kona is my go to color…always. I should’ve known. 🙂
2. Finally we are ready to assemble. After measuring the height we needed to cover the door frame, we used our Miter saw to cut the boards to the desired length (which was 74″ for our door). Then we placed them on the floor of our garage and started assembling. We put the tongue and groove pieces together with the gorilla glue.
Then we put the two side pieces of 1×2 (cut down to 74″ length) on each side using the Gorilla Glue on the back side of the wood and then nailing them down in place with our Nail Gun. The middle board we cut to 34 1/4″ length and measured down from the top around 45 1/4″ where the top of the middle board will go.
3. Then we cut the top and bottom pieces (1×6 boards – 34 1/4″ in length), gorilla glued and nailed those puppies down.
4. Next you will make the “X” on the bottom. This is what I consider the hardest part, but Rob told me “its just a little math” which is when I shut down (lol). We wanted a symmetrical “X”, so we measured the inside of the trim area. Meaning, measure from the inside top to the inside bottom of the trim and the outside left trim to the inside right trim to make a perfect square. SO confusing… I know. Here’s my attempt to show you what the heck that means. I’m a visual learner if you haven’t noticed.
Got it? So that gave us the measurement for the “X”. I can’t give you the exact measurements because my door may be different from your door. Just measure twice and cut once. That’s the builders rule.
So, once he cut the length, he then used the miter saw at a 45 degree angle to create the arrow look to fit perfectly in the corners.
Of course, we did the one solid piece first then measured the length to the center and cut, and did the same for the other side.
5. By the way, Gorilla glue was used before nailing down. I figured it was understood, but just in case, you’ll want to make sure that is done and secured.
6. All that’s left now is staining that bad boy! This is where my expertise comes in. I’m not a mathematician so I’ll stick with coloring or in this case…staining. 🙂
7. We brought the door inside to check our measurements and sure enough it was perfect. Plus I could hardly wait to see how it was going to look. I was GIDDY!
8. I started staining and then I put a polyurethane seal all over it for protection, and Rob started reading how to install the track. After careful consideration we chose to use one last piece of 1x4x6 Pine wood and paint it the same color as our wall right above where the door was being placed. You see, the problem was our studs in the walls did not match up with the measurements for the track system. I believe it was for a standard “stud” placement and we have a new home where stud measurements are farther apart. So, to make sure we can have a door that doesn’t fall on anyone and remain secure, we opted to use a piece of wood to mount into the wall first (into the said STUDS) and then install the track system as per the instructions. Yes, we are smart (lol).
9. Then the door handle. Oh I was excited now! It was ALL COMING TOGETHER so good!
Here’s the one I found at Home Depot. It was exactly the style I was looking for.
10. So then when that install was done I could HARDLY wait for the door to be hung, so Rob got to work and made the final step of this dream a reality.
11. Just so happened that I had the cotton wreath from Hobby Lobby ready to go. What? How did I do that? Ha, ha. I made good use of my 40% off coupon that week! I used a Command Strip hanger (didn’t want to nail into my new door) and after he hung the door I hung my wreath.
12. Just. Look. At. That. Viola! It’s perfection. Now I have to remove the laundry room’s existing door and start working on that rooms makeover, but for now… Mama’s happy.
13. Lastly, we screwed the guiding track piece for the door that came with the Track system into the floor. This was stressful for my hubs who didn’t want to ruin our wood floors, but without that little guiding track piece the door would’ve swung and may have been a huge hazard! So we bit the bullet and went with it. PS. It was totally easy and fine. SO glad we did that step. You can’t even tell.
14. So to recap: With just limited knowledge and a LOT of excitement, we were able to complete this DIY Barn Door project in three days and for under $100.00. Creating “one of a kind” home decor is so fulfilling. If we can do it, YOU can do it. Promise. So, gather your tool belt and your lumber and get building. This heirloom will stay in our family for a long time. I’m not trying to sell it or part from it until I’m dead. I’ll let my kids fight over this amazing door their mom and dad made together to beautify our home.