Were You Born in a Barn? No, I Just Like the Door.

In: Home Decor Tutorials
diy barn door tutorial

Simple and Inexpensive DIY Barn Door Tutorial

Yay, I’m so excited to share this tutorial with you all!  I’m a little freaky deaky when it comes to anything farmhouse related.  Unfortunately, I do not live in a farmhouse, but I’m doing my best to make my builder-grade house feel like there should be chickens running around and a cow outside the window.

With that said, I’m going to share this diy barn door tutorial with you today and then also give you two other barn door style plans to choose from.  Want to hear the most amaze-balls part?  They are ALL under $50 to build!!! And most of the wood can be cut by the guys at the big box stores!!!  Even better.

So, in a nutshell- you can have a gorgeous custom barn door and hardware for well under $100!!!  Let’s get started!

I came up with my barn door plan when I was inspired by an Instagram feed that I ADORE!  Jenna @Rusted_Design has an amazing feed and it would be ridiculous not to be inspired by it!  So, here we go.

Supply List for a 35″ wide by 83″ long DIY Barn Door- Option #1

  • 1 piece of 4′ x 8′ plywood siding
  • 4- 1″ x 4″ x 6′
  • 1- 1″ x 6″ x 4′
  • 1- 1″ x 3″ x 6′
  • wood glue
  • 1 1/4″ self tapping screws- this is so you do not have to drill pilot holes for every hole.
  • Clamps- very helpful for while screwing wood down.
  • sander with various grit sand papers.
  • Paint/stain
  • Miter saw

Cut List-

  • Siding cut to 35″ x 83″ –If you have it cut at the store, make sure you trim off each side evenly.  I did not so the planks are not even.  It doesn’t bother me that much, but some people it probably would drive them cray-cray.
  • 1 x 4’s—  2- 35″ long  2- 27″ long  2-43.5″ long
  • 1 x 6 —  35″
  • 1 x 3 —  cut to fit your diagonals starting at the top corners.

Step 1:

Sand the plywood siding with heavy grit sand paper.  I used 80 for the first pass, then 120 for the second.  It makes a huge difference.  It’s totally worth it to take your time here.  I promise.

sanded plywood siding


Step 2:

Assemble the trim pieces and attach to the door.  In this progression, spread glue on the back of each board before screwing in place.

  1. Top 35″ 1 x 4
  2. Both Side 27″ 1 x 4’s
  3. Middle 1 x 6
  4. Both Side 43 1/2″ 1 x 4’s
  5. Bottom 35″ 1 x 4

Applying wood glue to the back of a board for a barn door


Step 3:

Now to measure and cut the “X” for the bottom of the door out of 1 x 3’s.  I used a framing square to get the job done right.

Framing square to cut angles on a barn door


I added way more screws than were necessary to hold the door together.  I just wanted a more industrial aesthetic.

Screws in board


I clamped the sides for a little while after screwing together just to allow the glue to dry a bit.

clamped diy barn door


Step 4:

Now it’s time to paint or stain.  Honestly, I do not know how the plywood siding will take the stain.  I didn’t try it because I wanted a white door.  I would test a piece of scrap before deciding to paint of stain.

Step 5:

Add the hardware to the door.  I used carriage bolts to hold the steel bars with the wheels in place because I like the way they look.  On the back, I just put a nut cap.  For this and all hardware supply list, please see my Barn Door Hardware Post.


diy barn door hardware

For the handle, I bought a $0.50 cent handle at Habitat ReStore forever ago and it works perfectly for this door.  I usually pick through all the handles and pulls when I go there and bring some home for my stock.  Perfect for refinishing furniture.

I spray painted all hardware, with the exception of the wheels and the screws, satin black.  The door is just off the shelf Olympic White Paint + Primer in Semi-Gloss.  I always have a can in the house for trim and touch up.

Step 6:

Now you need to install some stoppers, just so the door doesn’t fall off the ends of the rail.  I used small “L” brackets.  Super easy solution.  I put one on each end of the rail and then one on the floor to keep the door from swinging out from the bottom.  I also added a piece of felt to each so that the door would not get scratched and it has a soft landing.  Works like a dream!

diy barn door hardware

DIY Barn Door Hardware


And that’s it!  Can you believe it?  I can’t believe how easy it actually was.  The door was built in a couple hours, but the painting took a while.  I hate waiting for paint to dry.  I’m so impatient.

Finished DIY Barn Door with English Mastiff


Reggie supervised the entire process so you know it was done right 😉

Now for the other two plans.  I did my best to write them up as tutorials without the actual pictures.  These are just “Plans in Theory” that I wrote up when deciding how to build my barn door.  Please feel free to use them as inspiration or a jump off point in designing your own door.

The overall supplies and sizes are the same, just the designs are different.  Using the plywood siding is not only a cheaper option, but so much easier in my opinion.  Let me know what you think!

DIY Barn Door #2- 

sketch up diy barn door plan

DIY Barn Door #3

sketch up diy barn door plan