DIY Network

Sliding Barn Door Installation From "DIY to the Rescue" episode DTTR-213

After the installation, the sliding barn doors provide a stylish way to soundproof the room.

The Alfieros loved the look of the shutters and barn doors they had seen while vacationing in Cape Cod. The couple felt the doors would be a good way to add privacy to the room and block the noise of Erik's drums.

The Alfieros' barn door was constructed using 3/4" tongue and groove planks held together with two1/2" thick vertical stiles and two horizontal rails on both sides – for a total frame thickness of 1-3/4", which makes for a sturdy door. In addition, the planks are supported with 1/2" cross bucks to form an "X" on one side of the door and give it a "barn door" look. Because the construction is very sturdy, this design could be used for even larger spaces.

Materials:

Safety goggles
Gloves
Tape measure
Level
Sliding barn door system and hardware (including 2" flat steel track, track joint brackets, spacers, screws, lag bolts, carriage bolts, hanger rollers, bottom roller guide and bottom rollers)
Saw with metal cutting bit
Drill with metal drill bit
Awl or punch
Cutting oil
Wooden mounting board
Router with half-bit
Black paint
Drywall anchors
Socket wrench

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	Figure A
	Figure B

1. To securely hold the track to the wall and add support for the heavy barn door, the crew decided to cut a mounting board the same length, but a little wider than the track. Drywall anchors, spacers and lag bolts are used to secure the track (and will hold the door rollers in place). The crew painted the mounting board black to blend with the track and routed the edges of the board for a more finished appearance.

   
   

2. Assemble the flat steel track with joint brackets according to manufacturer's instructions. Cut track to width needed -- in this case, twice the width of the door to allow the door to open the entire width of the door space.

   
   

3. Next, measure and drill holes in the steel track where it will be attached to the mounting board and wall (figure A). Use an awl or a punch to create a seat for the drill bit so it doesn’t slip on the metal as you’re drilling. Also apply some cutting oil to the area to keep the area cool. Wear safety goggles and heavy-duty gloves, as the metal will get hot.

   
   

4. Measure for the track system, and check with a level. Install the track and spacers to the mounting board and wall using lag bolts (figure B).

   
   

5. Attach hanger rollers to the door according to the manufacturer’s instructions, using the supplied carriage bolts, washers and nuts. Use a socket wrench to tighten.

   
   

6. Attach the bottom roller guide and rollers and hang door (figure C).

Custom Built Barn Door = $450
Custom Barn Door Hardware = $725
Total Cost of Barn Door System = $1,175

Barn Door Professional Installation = $2,775
Cost of Materials (above) = $1,175
Amount Saved by Doing It Yourself = $1,600

RESOURCES :
Barn Door Hardware and Track System Crown Industrial Hardware
(Specializes in hardware for gates, barn doors, custom doors, industrial items and rolling library ladders.)
213 Michelle Court S.
San Francisco, CA 94080
Phone: 650-952-5150
Web site: www.crown-industrial.com