Past Project: Herringbone Barn Door

DIY Herringbone Barn Door

Barn Door 2

This barn door is has become one of my favorite features in the cabin.  I was thinking that I could use something to separate the kids’ bedrooms and bathroom from the main living area, which only had an open hallway. After considering the options, a rolling barn door seemed perfect to turn that space into a “kid zone” while providing an unexpected decorative feature in the living area.

I built this barn door last summer from some reclaimed weathered barnwood that I found at a local salvaged lumber store. After getting a lot of ideas from Pinterest, I fell in love with the herringbone pattern. It looked simple enough to make and had the type of modern rustic look that I was after. Then in order to dial up the “industrial” vibe, I decided to wrap the whole door in raw steel channel iron.

To build the door I first measured the hallway opening, designed the door to overlap by a couple inches, and built the frame from 1×4 whitewood lumber. You can see the frame in this rear view photo of the barn door.

barn door rear


Then I trimmed the barnwood so that each piece had a clean 90 degree edge and laid out them out at a 45 degree angle, with the centers overlapping the middle board of the frame for support. After I placed each of the pieces, I started by gluing them to the frame. When it was dry, I flipped it over and screwed the boards in from the backside. Next, I trimmed the edges flush to the frame so that the wood portion was complete.

The steel framing was not quite as easy as I thought it would be. I bought 1.5″ channel iron from a local steel supply company (Everett Steel) and realized  that I needed to sand down the wood door edges to get it to fit neatly inside the channel. I cut the channel iron to length using an angle grinder and fit it around the outside of the door. I then adhered the steel to the wood using Liquid Nails and clamped it until dry. Ideally I would have welded it together, but I don’t (yet) own a MIG welder.

As a finishing touch, I decided to oxidize the whitewood rear frame using a steel wool and vinegar mixture. That made it look “old” like the rest of the boards. I loved how the old red barn paint shows through on the back side of the door. I bought the rolling door hardware from Rustica Hardware with the gear wheels and raw steel finish. By the way, their website is an awesome resource for barn door and track inspiration :). I used an extra piece of baseboard (rustic alder in a dark walnut stain) to mount it to the wall. It helps to use a mounting board in case one of the track holes does not line up to a wall stud. My hubby helped install the hardware and hang the door. And … Viola!

Barn Door 1Barn Door 3Barn Door 4Barn Door 2


Hope you enjoyed the barn door project! As always, love to hear your comments :).




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