Do you love the look of barn doors but not the price tag? We've got a DIY Barn Door and DIY Barn Door Track tutorial – that won't break the bank!
Dean and I dreamed about building a sliding barn door for our house for years. But the cost was always a wee bit prohibitive.
Have you ever felt the same way? Like you want a barn door but it's too expensive?
Well no more, because we've got a DIY tutorial for a barn door AND track that won't break the bank!
We were initially going to use reclaimed barn boards for this barn door project and tutorial. After all what better project to use barn boards for than a barn door?!
But when we went to look at them at a shop in the city they were about $20 a board and really rough to the touch. I'm talking snag-your-best-sweater-from-a-foot-away kind of rough. Which would sort of hamper the cozy feeling in your home, yes?!
So we decided to go for Plan B. Wood Pallets.
These can usually be found almost everywhere…the side of the road, big box stores, free exchange sites, etc.
In our case, Dean had a couple of really chunky wood pallets at his work that his company wasn't using anymore. He dismantled them and chose fifteen of the straightest boards. They were dinged and worn and full of character, but they weren't all wonky and warped, if you know what I mean.
TIP: When choosing wood for your door try to find the straightest pallet pieces so your door won't have a wonky “wow” to it.
After you've chosen the wood for your barn door, you'll rails and wheels.
One of the reasons we personally let this project drop to the bottom of the list for so long was figuring out the rail and wheels for the sliding action. Typically buying the barn door hardware from somewhere costs several hundred dollars. But you can always get creative. This time my most talented hubby thought of using two of the kids' broken scooter wheels minus the rubber and tubing!
Then you need to source the material for the rustic handles.
Since any large rustic handles that can be pre-purchased are rather pricey, we decided to DIY some really large handles using pipe fittings.
So, with that explanation, below you will find the supplies list for this project and links to each stage of the project as well.
PLEASE NOTE: You will need to measure your own doorway and make adjustments to the measurements to fit.
Supplies
- scooter wheels (with rubber removed) or pulley wheels (disassembled pulleys) qty=2
- 1-1/4″ x 1/4″ x 86-1/8″ long steel flat bar qty=2
- 1-1/2″ x 1/4″ x 84″ long steel flat bar qty=1
- 3″ x 1/8″ x 84″ long steel flat bar qty=1
- 1/2″ x 1/16″ x 2″ long steel tubing qty=7
- 2″ x 6″ x 48″ long wood qty=15
- fitting black iron floor flange 1″ qty=4
- fitting black iron 90 degree elbow 1″ qty=4
- black steel pipe nipple 1″ x close qty=4
- black steel pipe nipple 1″ x 16″ long qty=2
- 1/4″ x 1-1/2″ long plated lag bolts qty=60
- 5/16″ x 3-1/2″ long plated lag bolts qty=7
- #12 x 1-1/4″ long screws qty=16
- 5/16″ x 2″ long – 18 thread plated hex bolts qty=2
- 5/16″ – 18 thread plated hex nuts qty=2
- 5/16″ plated flat washers qty=4
- Minwax Dark Walnut stain
- Rust-Oleum Oil Rubbed Bronze spray paint
- white or light grey paint
- water
- sandpaper
After gathering your supplies, click on the links below to be taken to each step to build your own DIY Barn Door and DIY Barn Door Track That Won't Break the Bank!
xo,
Shannon
P.S. If you missed it you can click here for our original Upcycled Barn Door Reveal.
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Me encanto.
How much did the whole project cost?
Um, if I remember correctly about $200?
Def a lot cheaper than buying them! It looks great, I think I’ll try this for my living room!
Beautiful results. Could you provide some links where to purchase the flat bars and tubing?
Thanks,
Ponce
Hello Ponce. Metal Supermarket’s online purchasing site is here: https://ecommerce.metalsupermarkets.com/MSC-Home.aspx. Cold-rolled flat bar is here: https://ecommerce.metalsupermarkets.com/catalog/STEEL-COLD_ROLLED/FLAT_BAR/C1018.
For my birthday I asked my husband to build a sliding barn door for my office. He has been having a hard time finding affordable barn wood, so I really appreciated your suggestion to try using pallets instead. I will pass this information on to him and cross my finger for a great birthday surprise!
Here’s hoping!
We love your barndoor! Did much do we just built one for our house :). Before we hang it, my hubby wanted me to ask if yours is holding up okay without any support on the back. Ours seems a bit flimsy so we were just wondering. Thanks so much!
PA – love your kitchen, too 🙂
It held up just fine – until we moved and took it down! 😉
LOL. Thanks so much for getting back to me so quickly. I checked our receipt and it appears we purchased 1/8″ thick steel. The problem is with us. However, since the door will be visible from both sides when shit, I wanted the back side to be done, too. So the error works out for the best 😉
Oh my… I meant totype shut. So sry.
And say we are going to attach the right thickness of flat steel on the backside of the doors so all works out perfectly
I scoured the comments looking for this question before I asked it and didn’t find it! I can’t tell if your doorway has trim or not, do these plans factor in a doorway with trim? Or what precautions can I take that will help me best hang the door? I saw on one of the posts there’s something of a spacer, I think.. Would I just need to get that material in a bigger size?
I’m so excited to start this project this weekend! Thank you for posting!
Hello Jennifer. The doorway itself did not have trim. But there were baseboards for sure. The spacers and track allowed the door to open and close freely without touching the baseboards.
Hi Shannon,
I love these plans and I’m about to tackle this project. It looks like the links in the supplies list to Amazon items are broken.
Is there any chance you could update them? Or maybe confirm that they’re working for you?
Thank you.
Sandy
Oh dear! That’s crazy. They worked for me from the writing side of the blog, but not on what you would see. I’m so sorry! I think I’ve fixed them. Please try again, Sandy!
Thanks for having a look at it. Oddly, it’s not working in Chrome, but it worked just fine in Internet Explorer. That’s me trying just now. Anyway, I was able to get where I needed to go, and I’m excited to get going on this!
Weird. I’m glad you could make them work. I apologize again that it was difficult!
Can’t wait to get started on my barn door
Woohoo! Let us know how it turns out, Gretchen!
I absolutely love this idea. I too have seen the horrific high prices for barn doors and your idea is way more cost efficient for me!! One question, was the door heavy once it was completed and hung?
It was rather heavy, yes.
VERY nice. Where can i buy the long steel flat bars?