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]

Welcome to the Bunnings Workshop community @shaqqi. It's sensational to have you join us, and many thanks for your question about creating a barn door.

Creating a barn door from scratch would be considered an intermediate woodworking project. I don't want to discourage you from attempting it, but you should be aware that it is a relatively in-depth project. You might like to check out @jwatt's Sliding barn door for inspiration. They used Pine lining boards and framed them with DAR Pine. I've created a rendering below to assist in your build.

Typically you'd want the width and height of the door to be slightly larger than the opening so it covers it when closed. So, you could make your door 2200 x 1000mm.

Please let me know if you have any questions.

Mitchell
 

[MitchellMc]

Hi again @shaqqi,

I thought I'd also link you to our wide range of barn doors for you to take a look at too. Just in case you don't decide to go ahead with your D.I.Y. project.

Mitchell

[shaqqi]

Thanks Mitchell for the guidance and sharing the posts 

After your post and research  I came to a conclusion that i will give it a go as i am confident i can do that but still some expertise guidance i will be needing to progress . Design i am going to build is attached for reference. There are 2 options i concluded to go from. Please advise which will be better option. Reason for asking is the overall thickness difference between both options

Option 1 (Total door thickness will 12+19 = 31mm)

Pine Lining Boards  (12 mm thick only available in Bunnings ) Main 140 x 12mm 4.8m Unprimed Solid 321 Lining Board

And

Frame with DAR Pine of 89x19 mm or 140 x 19mm dressed pine. (available in Bunnings)

Option 2 (Total door thickness will be 19+19 = 38mm)

DAR Pine of 184 x19 mm (6 pieces to join) or 140 x 19mm (8 pieces to join) dressed pine.

And

Frame with DAR Pine of 89x19 mm or 140 x 19mm dressed pine.

Also suggest screwing or nailing is better, appreciate if share the recommend screw/nail size to buy for recommended option

Thanks 

Hassan

 

[JacobZ]

Hi @shaqqi,

That's brilliant, I'm glad you've decided to give it a crack.

Regardless of the thickness, option 1 is my choice. The main reason for this is that the 140 x 12mm Lining Boards are manufactured with tongue and groove edges so they lock together far easier than DAR pine does.

It's also worth noting that if the door is likely to be viewed from both sides you may want to add the 19mm DAR on both sides of the door so it is uniform regardless of which side you are viewing. This will make the door 50mm thick.

To make your door as strong as possible, the 140x12 lining boards should be glued together and then clamped while the glue sets. Due to the width of your door, you'll have to use some decent-sized clamps such as these Craftright 1200mm T-Bar Sash Clamps. 

Brad nails are the best option for attaching your DAR to the lining boards as they are designed with a narrow head that sinks below the surface of the timber so they can be covered with timber filler. Unfortunately, they require a nail gun to be effective. As they are extremely thin, hammering them manually is not usually a viable option.

25mm nails are the only size brad nail that will work if you choose to put the trim on only one side of the door. These PowerFit 25mm C Series Electro-Galvanised Brad Nails can be fired by this air bradder, but unfortunately, it will also require an air compressor to function. You'll have to contact your local store to check for availability. 

If you put trim on both sides of the door, you can use longer nails such as these 38mm Angled Brad Nails which can be fired by this Trim Master Gas Bradder. Once again, you'll have to check with your local store for availability.

Let me know if you have any further questions.

Jacob

[shaqqi]

Hi Jacob

Thanks for guiding the way forward and the links. Its very helpful. 

I will be proceeding with below please confirm that is correct arrangement 

140 x 12mm Lining Boards are manufactured with tongue and groove edges (Clearly understand clamping and glued thing. Can do that)

Frame  (Vertical / Horizontal on door corner sides) with DAR Pine of 140 x 19mm dressed pine. (available in Bunnings): Going one side only

Frame  (Horizontal in middle) with DAR Pine of 140 x 19mm  dressed pine. (available in Bunnings)

I have to trim 2 x lining board edges (5 ~ 10 mm) which are at door left and right edges to make it flat both ends and will align with Frame DAR Pine. 

But please advise the best alternate way regarding Nails/Screws. As going with rental/hire options is a bit hassle i prefer to buy and use it in best suitable and economical way . Please advise the nail/screw to sue which i can but the nail gun (for infor i already have the drill/machine so screw can be used)

Also share some guidance how many nails/screws is required to each joining point between lining boards and DAR frame . If there is any sketch layout available or guide It will be very helpful. I want to nail them to minimum level enough to be strong /durable . I have shared the nailing pattern in pic like 4 nails on each corners of door wherever the  lining boards and DAR pine are joining. Appreciate your response 

Thanks  

Hassan

[JacobZ]

Hi @shaqqi,

Brad nails are the better option because they are much easier to hide than screws are. 

You can use either this Ryobi 18V ONE+ 18GA Brad Nailer or this Ozito PXC 18V Cordless PXNGS-018 with these Arrow 25mm Brad Nails.

See the below image for my recommended nailing pattern.

I'd also suggest applying some wood glue to the back of your trim pieces before nailing them in place. The glue can be spread liberally so any gaps between the nails are also held tight to the lining boards.

Let me know what you think and if you have further questions, please don't hesitate to ask.

Jacob

[shaqqi]

Thanks Jacob for the photo and advise 

Definitely i will ask all the queries to make it right first time and will be an example for new comers

Below are my few queries if you can share your expertise 

1. Please suggest the best wood glue with link to use to combine lining boards along with qty of glue required

2. How much time shall i leave them to cure after clamping 

3. Shall i do sanding of lining boards prior to combining all ( I will do staining afterwards) or leave sanding at the time for staining 

4. Do i use wood filler on nails or nails head will be cover in staining itself if have to use please share the filler link to use 

&

5. Barn door track for Door width approx.1100 mm and thickness = 31 mm (all i can find in bunnings are for 2000 m width and thickness suitable from 35 mm onwards )

Thanks

Hassan

[JacobZ]

Hi @shaqqi,

The more information our readers can get the better, so thank you for asking.

1. Gorilla Wood Glue Ultimate and Sika 1L Sikabond® PVA Adhesive are both very good options. I can't say for sure how much you will need, but I would be surprised if you need more than 1L of either.
    
2. At minimum 4 hours, preferably overnight.
    
3. A light sand is worthwhile, but I wouldn't go overboard because some glue will squeeze out of the joins and will need cleaning up after. 
    
4. Timbermate Pine Wood Filler should be used on nail holes and then sanded before staining.
    
5. Because of the width of your door, you will have to go up to a 3m track. This Rolltrak 3000 x 40 x 6mm Barn Door Track Matte Black Side Mount will work with your door, however, you may need to shorten the bolts that are provided. If necessary, this can be done with a hacksaw.

 Let me know if you have any further questions.

Jacob

[shaqqi]

Thanks Jacob 

Today is Bunnings shopping day

• Is it possible to nail  25mm-c-series-electro-galvanised-brad-nails    or  arrow-25mm-brown-brad-nails .using  pinnacle-hardware-nail-holder  ?
• Rolller track you mentioned is of 3 m length . Will it not be too long for 2.2 m door. We don't have any like 2.5 m length ?

Thanks

Hassan