How to build a barn door with VJ panels

[lifestylebymari]

Difficulty: Intermediate

Barn doors are a great way to create privacy in your home. They can also be used to add style and character.

Here is a step-by-step guide to creating a custom barn door. You can use our measurements or adjust them to suit your own set-up.

As this project involves power tools, please follow all safety guidelines provided by manufacturers and use the recommended protective gear.

Let us know if you have any questions. We’d be happy to assist.

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Steps

Step 1

Measure and mark your VJ panel sheets.

Determine the width and height of your wall opening by using a tape measure. Then add 50mm to both the height and the width to ensure the door is slightly taller and wider than your opening.

Mark out your custom measurements on your VJ panels with a tape measure. My door measured 908 x 2400mm.  

Step 2

Cut the VJ panel sheets.

Cut out your VJ panel sheets based on your marked measurements with a circular saw. Don’t forget to wear personal protective equipment (PPE) while cutting, including safety glasses.

For straight cuts, you can place one of the sheets on top of the other as a guide. Use clamps to secure them.

Step 3

Mark and cut a border frame for the VJ panels.

Place one of the cut VJ panel sheets downwards on a flat surface so that the back is facing upwards. 

Now take two lengths of 2400mm 42 x 19mm dressed Pine and cut them to match the length of your vertical sides. My sides measured 2400mm each so I didn't have to cut the lengths.

Place those on the sides of your panel and measure the distance between them. Cut four lengths of the 42 x 19mm dressed Pine to suit. I cut four lengths measuring 900mm.

Place two lengths horizontally on the top and bottom sections of the VJ panel sheet. Then place the remaining two lengths in the middle. Make sure they are evenly spaced. In my case they were 900mm apart.

All the dressed Pine lengths should fit perfectly when placed together to form a frame split into three sections.

Step 4

Secure the dressed Pine frame to the VJ panel sheets.

Apply pea-sized amounts of construction adhesive on the outer side of the dressed Pine frame, spaced about 5cm apart. Then place a second VJ panel sheet on top of the frame and glue the sheet and frame together. Make sure the grooves of the sheet are facing outwards away from the frame. Don't use too much adhesive for this step as it can leak. 

Once dry, flip the VJ panel sheet and glued frame so that the frame is facing upwards. Apply adhesive on the outer side of the dressed Pine lengths again and then place the first VJ panel sheet on top of the frame, gluing them together. As with the previous sheet, the grooves should be facing outwards.

Your frame should now be in the middle of two VJ panel sheets, forming a door.

Step 5

Nail your VJ panels to the frame.

To secure the door further, nail the dressed Pine frame to the VJ panel sheets. Draw a small cross or arrow to mark your nail points along the areas where the sheets and frame intersect.

Now use a nail gun to nail six nails on the sheet along both vertical sides of the frame lengths. Then nail three to four nails along the top and middle of the sheets. Make sure to press down on the sheet while nailing to avoid any gaps between the sheet and the frame.  

Step 6

Fill any holes on your door.

Use a gap filler to fill in any small holes created by the nails. Apply a small amount of gap filler in any holes using a scraper. Make sure the hole is completely filled.

Let the filler dry for 30 minutes.

Once dried, sand it by hand using a 120-grit sanding paper for a smooth finish.

Step 7

Make a hole for the flush pull handle. 

Measure and mark out your preferred spot for the door handle. I placed my handle 100 cm away from the floor and 39cm away from the right edge of the panel.

Once you've marked the handle spot, drill a hole measuring 51mm in diameter using a drill driver with a holesaw attachment. 

Wipe off any sawdust using a damp cloth.

Step 8

Once your door is clean and dry, it’s time to start painting. I chose two different colours for both sides of the door. I went with a white colour to match my walls for one side and chose a darker colour for the other to create more depth and interest.

Use a 100mm x 4mm roller to paint the first side of your door. You can also use a brush when painting over the grooves. Apply two coats for a better finish. Wait approximately two hours for the first coat to dry before applying the second.

Leave the painted side of the door to dry for 24 hours. Then flip the door and paint the second side, repeating the process.

Step 9

Install the flush pull handle.
 

Once the paint has fully dried, apply adhesive on the inner side of both pieces of the flush pull handle and glue it into the door from both sides. There will be a small hole on one side of the handle. Make sure to position the handle so that the hole is on the side where the dressed Pine frame is.

Now use a screwdriver to screw in the small screw provided into the frame.

Your VJ panel barn door is now ready for installation and use.

      

Materials

• 65mm stainless steel round flush pull handle two pack 

• Two sheets of Easycraft 2400 x 1200mm 9mm Lining Panel White MRMDF Primed VJ 100mm 

• 32mm nails
• Gap filler 
• Construction adhesive

• Two lengths of 42 x 19mm 2.4m DAR Pine Premium 

• Two lengths of 42 x 19mm 1.8m DAR Pine Premium 

• Paint 

• 120-grit sanding paper.

Tools

• Pencil
• Tape measure
• Drill driver
• Five piece hole saw set
• Clamps
• Nail gun
• Paint roller
• Paintbrush with tray
• Damp cloth
• Safety glasses
• Screwdriver.

Images

                      

[Akanksha]

Hello @lifestylebymari,

Thank you for sharing this guide to building a barn door. It can be a wonderful and cost-effective way to immediately transform spaces and add a rustic charm to your home. 

For anyone looking for tips on how to install their barn doors after building one, check out this step-by-step guide: How to install sliding doors.

Akanksha 

[BoeingFan]

Thank you so much for sharing @lifestylebymari this looks fantastic.

[lifestylebymari]

It was my pleasure! I love how it transformed my place and hope it can help and also transform someone else's place  

[debc]

@lifestylebymari , this looks fantastic thank you for sharing it is just what I need. I have an area with an ensuite and not far from it a walk-in robe neither have doors on them and I would like a barn door but regular barn doors look too heavy for the area so I'm definitely going to give this one a go 😊

[MitchellMc]

Keep us updated @debc, and reach out if you need any assistance. I'm sure @lifestylebymari and the rest of the community would be more than willing to share advice.

I can't wait to see some pictures of your project.

Mitchell

[debc]

Thanks for the encouragement 😃 however I was talking to someone with a bit of building experience about this and what a great idea it is.  They then suggested it may not be a suitable material to use on an ensuite door because of the moisture.  Would anyone know if this would be a problem?  Thanks for any help 😃

[MitchellMc]

That's certainly something to think about, @debc. My immediate thought is that standard hollow-core doors, which you would use for bathrooms, are constructed from MDF skins. Not to mention the cardboard internal honeycomb. The painted layer is what gives them protection from moisture. On a side note, have you ever wondered why the first sign of damage on an entrance or bathroom door is swelling on the lower edge? It's because, typically, we install doors and then paint them. Due to this, people forget to paint the bottom of the door and leave the exposed timber/MDF. Water is then sucked up into the door, and the timber expands. Anyway, that's a bit of a tangent.

If you are concerned, then the simple answer would be to use Easycraft 2400 x 1200mm 9mm Lining Panel White MRMDF Primed Wet Area 100mm instead of the standard panelling. This panelling is designed for use in areas subject to high humidity, like bathrooms. It's a smart choice to ensure extra durability and moisture resistance.

Please let me know if you have further questions.

Mitchell

[jfo888]

This is great and how I plan on making a door for our lounge room. Thank you @lifestylebymarii

[MitchellMc]

Keep us updated on your project @jfo888, and please reach out if you need any assistance with it. 

Mitchell

[andrew91]

Hi lifestylebymari

In Step 4 how did you secure the first VJ panel to the frame without upsetting the glueing of the second VJ panel please ? some type of clamp

Andrew

[MitchellMc]

Welcome to the Bunnings Workshop community @andrew91. It's brilliant to have you join us, and many thanks for your question about this wonderful project.

Hopefully, @lifestylebymari can provide some advice. However, I do note she suggests allowing the glue between the frame and the first panel to dry before flipping the board over and glueing the second panel in place. So, we can assume that the first panel is held firmly in place with the glue and won't be upset by you attaching the second board.

Clamps are always a handy accessory to have available for such jobs. I highly recommend Irwin Quick-grip clamps.

Please let me know if you have any questions.

Mitchell