D.I.Y. barn door

[Bubbles8712]

Completed projectWe 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: 

V grooved : https://www.bunnings.com.au/2400-x-1200-x-9mm-internal-v-grooved-project-panel_p0390169

MDF board : https://www.bunnings.com.au/9mm-standard-mdf-1200mm-x-2400mm_p0590056

cheers

[splinters]

Basic rail fixed to the door casingFloor guideDoor closed off to toilet, opens laundry cupboard

[splinters]

@Bubbles8712 @EricL here is the current opening which I'm needing to close off with a custom sliding door.

From the front door into the lounge/dining

From the hallyway

OPENING

1490 wide

2050 high

PROPOSED DOOR

1600 wide - allowing for 55mm coverage when closed

2050 high - this should see the top of door sit approx. 10mm above the opening once mounted so provide enough clearance at the floor level

The more I marinade this, the more I think I'd like to use as small a head plate as possible. Maybe even just the same size molding as the side casing.

Side casing to be just a bullnose skirting really:

https://www.bunnings.com.au/hume-67-x-18mm-2-7m-moulding-white-mdf-primed-bullnose_p8470538

Head plate could be :

https://www.bunnings.com.au/66-x-18mm-5-4m-moulding-white-pine-fj-primed-dar_p0020750

Fixing gun top and bottom at each stud to fix the trim, then whatever screws - into studs - are recommended to attach the rail and hold the door?

If I go this way I could end up using something like this rail if I can get one the right length, which I think is over 3.2m given the size of door?

https://www.bunnings.com.au/cowdroy-915mm-60kg-centurion-sliding-door-track-set_p3985788

[Bubbles8712]

Agree with the smaller head plate - as long as it is solid timber, 18mm should be fine (though I’m not a carpenter!). 

We used five 14G x 85mm zenith screws to mount the 30mm thick timber header. Probably a bit over engineered but at least I know it’ll hold!

We used a barn style rail kit and installed as per instructions and supplied materials.

https://www.richmondau.com/product/country-style-black-steel-3m-barn-door-hardware-kit-bhr005/

Yes, you’ll need to use the 3.2m long kit as you need wiggle room either side. 

Also, the video below was quite helpful!

https://youtu.be/AAQNawp5GXo

[EricL]

Hello @splinters 

It's great that you've received excellent advice from @Bubbles8712. In regards to the materials that you've mentioned, they should work very well with your proposed plan. The Zenith 14G x 85mm Galvanised Type 17 Batten Bugle Head Timber Screws might be a tad overboard but remember that it is holding the weight of the door, the head plate itself and the dynamic forces applied to it. 

Speaking of door weight, if you are getting a custom door built it's important to take into consideration how heavy it is. You need to make sure that the track hardware is able to take the doors weight. I recommend having a look at the door track systems one more time before you make your final decision.

Whether you use pen and paper or a computer program, I propose planning it first so that you have a clear idea of the steps you'll be taking and the materials you'll need to use when you begin building your new sliding door.

Please remember to wear personal protection such as gloves, goggles and a mask when working on your project.

If you have any other questions we can help with, please let us know.

Eric