How To Build Modern Barn Doors for Your Home (DIY) | Family Handyman

3 to 4 days

Intermediate

$350 or more

The editors at Family Handyman magazine were lucky enough to get a tour of Mr. Build It’s newly rehabbed home on the outskirts of Boise, Idaho. You might know Mr. Build It — Alex Mazhukhin — from his show that streams on At Home With Family Handyman. The projects he does on the show are real-life labors of love from his home.

We’re happy to share an exclusive step-by-step to one of his most impressive builds: barn doors, rejiggered to fit in a home.

For more from Mr. Build It

Mr. Build It can be found on the At Home With Family Handyman streaming channel. At Home is streaming now on Samsung TV Plus, XUMO, The Roku Channel, LG Channels, Plex, fuboTV, Sling Free, and the Family Handyman app. It’s also available on iOS, Apple TV, Android, AndroidTV, FireTV and Roku devices.

Using a table saw, trim 1/8 inch from both sides of the 2x6s and 2x8s. This will make smooth edges for gluing.

Using a miter saw, cut twenty 24-in. lengths from the 2x8s.

Note: You may need more or fewer lengths depending on the desired height of your door. My doors are quite tall — 46 in. x 120 in.

Using a miter saw, cut a 30-degree slant on both ends of 1 length, going in the same direction, to create a parallelogram shape. Repeat with the remaining 19 lengths.

Alex Mazhukhin

For stronger glue adhesion between the angled lengths, use a Festool Domino joiner (to create mortise and tenon joints) or a biscuit joiner as well as the glue. Glue up the left side of the chevron pattern and do the same for the right side. Since the glue up will be slanted due to the chevron pattern, using long ratchet straps to hold the pieces together is helpful. Let the glue dry overnight.

Alex Mazhukhin

Using a track saw or a circular saw with an edge guide, trim the sides of the left and right chevron panels to create two even, rectangular shapes.

Alex Mazhukhin

Once both panels are ready, attach the center stile. Again, it’s best to use either the Festool Domino joiner or biscuit joiner, in addition to gluing, for a strong bond. Repeat the process with additional 2×6 material for the left and right stiles. Let the glue dry overnight.

Alex Mazhukhin

Repeat the process for the top and bottom rails of the door (use 2×6 material for the stile and rails).

Alex Mazhukhin

Round over the side edges of the door using a ⅛” round-over bit with a router.

Using a sander, sand the doors with 80-grit sandpaper, then follow up with 120-grit sandpaper and 220-grit sandpaper for a smooth surface.

Now, the doors are ready for your favorite stain. Two coats should give the wood a rich color. To prolong the life of your stain, roll on a light coat of polyurethane clear coat. Let dry.

Alex Mazhukhin

After installing your preferred pull or handle hardware, install the barn door slide-wheel hardware onto your door, following the manufacturer’s instructions. When installing the rail over the header of your door opening, be sure first to secure a 1×6 pine (primed) board, the length of your barn door hardware, onto the wall studs. This will ensure that you have adequate anchor points to support your new doors.

Alex Mazhukhin