Updated: Nov 23, 2019
BARN DOORS ARE HUGE right now! I have made a few different designs and I have my favorites for sure, but I have never built this design before and I love new projects! GUYS this one is so easy and it is a great first time door if your new to them. You will need to use a miter saw and possible a finish nailer if you have one.
So, I got a request to build a 3 panel barn door and I thought this would be a great tutorial! Its pretty simple and requires minimal tools.
To start, here's what you will need:
Miter saw or circular saw
4 - 1x4x8 pieces of poplar from Lowes or HD
3 - 1x2x8 pieces of poplar
3/4 birch plywood or another hardwood ply like maple or oak.
1- 1x6x8 primed pine board for header piecs
titebond glue - https://amzn.to/2sa4Rqe
clamps - I use Pony Jorgensen clamps like this https://amzn.to/33NiSYN
white primer - https://amzn.to/2OkZD28
white paint - https://amzn.to/33NiSYN
caulk - https://amzn.to/37v0FBG
optional - finish nailer with 3/4 inch nails
To begin -
I went to Home Depot and had them cut down the plywood to the door size minus the trim. In this case I wanted the final door to be 36" wide and 82" tall. The trim is .75" each and it will frame the door so a pieces on each side. So I took 1.5" off the width and height of the ply wood cut. The final cut for the ply was 80.5" tall and 34.5" wide.
Then, I cut the poplar to match, starting with the cross pieces for the top and bottom. Two pieces cut at 34.5" then I glued those onto the plywood. Use just enough glue to cover the poplar and attach to the ply wood with clamps. If you have a finish nailer you can use that to shoot a few nails in from under the plywood.
Then cut two poplar pieces at 80.5" and glue and clamp those in place between the top and bottom pieces and up against the edge.
Next, cut two more pieces for the cross section to create the 3 panel portion and these will be cut to 27.5".
Then I divided the 73.5" length in between the top and bottom cross pieces into three parts to figure out where I should glue the 2 cross pieces. For this door it was 24.5" which I marked on each side of the door. Then glued and clamped.
Then for the final two steps in the build process I cut the 1x2x8 pieces of poplar to trim out the door.
After this has cured, you can cut the frame out of the 1x2s that are left. I usually do the longer sides first and then the top and bottom. The side pieces will be 80.5" or you can just hold the 1x2s up to the side and mark with a pencil.
That's it! Now its done and ready to hang. I usually suggest this hardware for hanging.
Thanks so much for stopping by! I am happy to answer any questions you may have! You can also find me on the following socials.
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