How to Build a Sliding Barn Door
Construct a sliding barn door with character and DIY charm for less than $100!
The hardware with the sliding barn door system should include the following: 2" flat steel track, track joint brackets, spacers, screws, lag bolts, carriage bolts, hanger rollers, bottom roller guide and bottom rollers. In this project, the barn door is constructed using 3/4" tongue-and-groove planks held together with two 1/2"-thick vertical stiles and two horizontal rails (top and bottom) on both sides, for a total frame thickness of 1-3/4". The planks are also bolstered by 1/2"-thick cross bucks cut to form an "X" on one side of the door to give it a "barn door" look.
To secure the track to the wall and add support for the heavy barn door, cut a 1" x 4"mounting board the same length as, but a little wider than, the track. Use the drywall anchors, spacers and lag bolts to secure the mounting board. In this project, the mounting board was painted black and the edges rounded slightly for a more finished appearance.
Assemble the flat steel track with joint brackets according to the manufacturer's instructions. Cut the track to the length needed -- twice the width of the door allows the door to open the entire width of the door space, as in our example.
Next, measure and drill holes with a metal-cutting drill bit in the steel track where it will be attached to the mounting board and wall. Use an awl or a punch to create a seat for the drill bit so it doesn’t slip on the metal while you’re drilling. Apply some cutting oil to the drill hole to keep the area cool.
Measure for the track system. Using lag bolts, install the track and spacers to the mounting board and wall, making sure that the track is perfectly level.
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.With another person or two, attach the bottom roller guide and rollers, and hang the door on the track.