We are looking to build our own barn doors (2400H X 1200W) for 2 large openings in our living area. The design below is what we want to achieve.
We had originally planned on using individual pine planks attached to a thick piece of MDF, but to save time + money, we are now thinking of sandwiching together a piece of 9mm MDF Board with 2 pieces of 9mm 2 x 2400 x 1200 x 9mm V Grooved Project Panels (links to products at end of post). We would glue and then nail the V grooved panels to both sides of the MDF so we get the desired look on both sides of the door.
We would then screw in a horizontal 1200W X 235mm x 19mm Pine panel at the top and bottom of the door to add further stability and to attach the tracking/rail system to. This would bring the depth of the door to 46mm - which seems to be around the standard depth of a normal door.
My concern is whether the door will be too ‘flimsy’ as it will essentially be made out of 3 large 9mm boards. I will also be white washing and then sealing the door to help keep moisture out (even though it isn’t in a wet area).
What do you think? Do you think the door will hold up fine as described? Or will we need to attach another pine plank across the door to provide extra support? Something like this:
Success. We used five 14G x 85mm zenith screws to mount the 30mm thick timber header and then mounted the rail kit as per instructions and supplied materials.
Thanks for everyone’s input…certainly helped with clarifying what to do.
Wow incredible job @Bubbles8712. You must be so proud of what you've been able to achieve.
Thanks for sharing.
Very nice work! Visually it looks much better than the raw-style seen in your opening post.
May I ask which "Kreg" pocket hole system you used?
I used the 310 system with the 38mm screws (links below). It would have been quicker to have the more expensive Kreg system which allows you to make multiple pilot holes in the one go, but given I won’t be using it often, the single 310 one was fine. It is very easy to set up and use. I used the 19mm option on both the jig itself and the drill bit attachment. This resulted in all timber having about half of the 38mm screw length making the frame very sturdy.