How to build a barn door?

[shaqqi]

Hi All

This can be my first DIY Bunning project. 

I would like to make a wooden stain type barn door. Size of opening is width 980 mm width and height 2120 mm

Plz suggest what shall be the ideal width and height I shall go for and what material I shall get from bunnings . Thanks

 

[MitchellMc]

Hi @shaqqi,

Can you please confirm whether the wall is solid concrete or plasterboard over a timber frame? Or, perhaps there is a transition, and it's both?

For a concrete wall, you would drill holes in it where you wish to mount the timber, pre-drill the timber, and then fix it to the concrete with the Dynabolts. There are no timber studs in a concrete wall.

You would then fix the roller track to the support header.

Mitchell

[shaqqi]

Hi

Apologies I should have ask and clarify this first instead of jumping to stud and bolt. 

Barn door and support header is to be installed on a concrete wall. 

Wall thickenss is 110 mm

Sharing the photos of wall from both sides 

 

 

Please advise what is the best method to install the support header and share link of prosuct to be used. 

Thanks

Hassan

[JacobZ]

Hi @shaqqi,

If the wall is concrete/brick, there's not a lot of point in adding the timber header. The timber header is used when the mounting holes for the door track don't line up with the timber studs. By screwing the header to the timber studs and then the track to the header, you are using the header to attach the door to a structural element.

In your situation, as there is concrete or brick where you are mounting your door track, there is a structural element everywhere so there is no need for this header. You can simply use a suitable masonry anchor to attach the track to the wall. The Ramset 6 x 75mm Countersunk DynaBolt Plus Masonry Anchors that @MitchellMc mentioned earlier should do the trick.

You can use them following the door track manufacturers recommendations.

Let me know if you have any further questions.

Jacob

[shaqqi]

Hi Jacob

I am adding support header just for beautification purpose as it give nice look to the door. 

But still my preference is durability.

Suggest kindly shall go for direct installation or with support header

Thanks

Hassan

[JacobZ]

Hi @shaqqi,

That's fair enough.

You can still use the Dynabolts I've recommended above to install both the header and the track. 

You will just install the header as normal, but you'll have to predrill through the header so the Dynabolts you're using on the track run through the header and expand in the brick behind it.

Let me know what you think.

Jacob

[shaqqi]

Hi All, 

Thanks for your support , I am able to complete my project and install to the location and it looks perfect 

Sharing the picture to celebrate the success together

Thanks 

Hassan

[Jason]

Well done Hassan (@shaqqi) it looks fantastic. You should be proud of your efforts.

Thanks for sharing with the community, I'm sure it will inspire others. 

Jason

[JacobZ]

Thanks for the update, Hassan (@shaqqi ).

That is a mighty fine door you've put together.

I hope you will get a lot of use from it and are extremely proud of your efforts.

Jacob