Interior barn door construction & installation

DIY_Babe

Mission accomplished!!

I'd wanted to put something in this doorway for years. Whatever I chose needed to provide privacy to the bathroom hallway and bedroom that's behind it, and act as a divider from the 'front room' it faces into, but it was important that it didn't encrouch on the limited space around it. It also needed to allow easy access for my furbabies. That's not too much to ask is it? 🤔😬

Inspo finally kicked into gear while I was watching the latest season of The Block, then my barn door was born, and I'm loving it! 😍

Materials

• Leftover Tasmanian Oak from when my timber floor was laid 13 years ago. I had the exact number of pieces needed to make the width of the door I needed - it was meant to be
• 135 x 19mm Pre-Oiled Spotted Gum (for the hardware rail)
• Classic Sidemount Barn Door Hardware
• Square Barn Door Handle Kit (Double-Sided)
• Cabot's Water-Based Stain and Varnish - Walnut
• Selleys Liquid Nails
• Timber screws

Tools

• Ozito PXC 18V 165mm Circular Saw
• Ozito PXC 18V Cordless 1/3 Sheet Sander
• Diablo sanding sheets
• Craftright Folding Saw Horse (2-Pack)
• Ozito PXC 18V Cordless Drill
• Ozito PXC 18V Cordless Impact Driver 
• IRWIN 1270mm Quick-Grip Clamps
• Monarch paint brushes
• Trojan 900mm Box Level
• Stanley S100 Stud Sensor

Steps

Step 1

Saw timber to the lengths required for the door and door-frame layers.

Step 2

Sand all timber pieces with 80 grit, and finish with 120 grit.

Step 3

Glue the vertical planks of the door together and securely clamp for 24 hours.

Step 4

Glue the frame to the top of the vertical plans and securely clamp for 24 hours.

Step 5

Drill pilot holes, then screws through both layers to secure the frame to the door.

Step 6

Sand both sides of the assembeled door with 120 grit.

Step 7

Stain/varnish both sides of the door.

Step 8

Affix the door hardware brackets to the top of the door (to be hung on the rail), and the handle on the door.

Step 9

Install the barn door hardware above the doorway.

Step 10

Hang the door on the rail, and enjoy! 😎

View my highlights reel of the whole process here.

JacobZ

Hi @DIY_Babe,

Welcome to the Bunnings Workshop community, and what a way to introduce yourself.

You should be incredibly proud of yourself to take on and produce such a high-quality door with some basic tools and a bit of elbow grease. I'm a huge fan of black hardware contrasted against timber, so this ticks a lot of my style boxes and might I add that the cutout for your fur babies is a fantastic solution that provides easy access while still giving the privacy that you require.

I hope to see more projects from you in the future if this is the standard you've set for your first.

Jacob