How to Build a Simple Rustic Barn Door (DIY) | Family Handyman

Multiple Days

Intermediate

$251-500

If you’ve investigated rustic “barn” doors, you’ve probably gotten sticker shock. Here's how to save your money by taking the "DIY" approach to building a barn door.

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Before you start shopping for barn door hardware, take a careful look at the area where you would like to install the barn door and figure out what door setup works best.

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To support a door, the track needs to be solidly mounted to wall framing. There are three options.

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Some sort of spacers or stand-offs that hold the track away from the wall, allowing the door to slide freely, will be included in the track mounting DIY barn door hardware.

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You’ll need a guide at the floor to prevent the bottom of the door from swinging.

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We used inexpensive 1×6 No. 2 pine boards, cut rabbets on the edges to make shiplap boards, and distressed and stained them to resemble old barn wood. When you choose boards, don’t worry about knots, scratches or gouges. But try to pick boards that are straight and not cupped or warped.

Use a brush knot cup mounted in an angle grinder to abrade the softwood and expose the grain. This gives the wood a weathered look.

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If you want to take your distressing to the next level, use an awl to create “wormholes.”

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Most stain brands have colors that will work well for aging wood. Here are the colors we used:

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The steps you take to mount the track will depend on your track support. If you’ve installed continuous backing between the studs or are mounting the track on a header board, then you may be using a predrilled track and can proceed to bolt the track to the wall.

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With the track mounted, finish the job by putting the door on the track.

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