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Insulated Barn Style Wood Door

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Project by BobbyTheNewbie posted 10-18-2015 02:06 AM 766 views 1 time favorited 4 comments Add to Favorites Watch

We wanted to do something special for our dad’s birthday so we decided to convert their 10’x20’ Tuff Shed pool house into a home office for him. While in the planning phase one of our road blocks was the door. It was an odd size and did not seal. So we decided to re-frame the rough opening and build a custom wood door.

I’ve never built a door before, so I hopped on google and read some articles on different styles. Taking a little from several articles, I came up with this.

The inside is 1×6 red oak for stability with half lap joints – a first for me doing this style joint. I then used 1/4” sheet of maple plywood on one side. Once the glue had dried I flipped it over and used foam board insulation and then spray foam insulation inside the for openings. I put a sheet of maple plywood on the other side and then took furring strips ripped in half and framed the 2 faces to give it the barn door look. Capped off all the way around with trimmed down 1×3 red oak.

My brother Travis who is also on Lumberjocks helped with the stain and then he applied the clear helmsman spar. Once installed we used 1×6 rough cedar casing for the rustic look. Was a really fun project. Not perfect, but a lot of fun. Always happy to hear ideas/critiques! Thanks for looking.

-- Bobby, Texas





4 comments so far

View Jim Jakosh's profile

Jim Jakosh

17148 posts in 2568 days


#1 posted 10-18-2015 12:07 PM

Great job on that door. It looks real sturdy

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View BobbyTheNewbie's profile

BobbyTheNewbie

8 posts in 429 days


#2 posted 10-18-2015 12:23 PM

Thank you sir!

-- Bobby, Texas

View GerardoArg1's profile

GerardoArg1

940 posts in 1456 days


#3 posted 10-19-2015 02:18 PM

Nice job. Like a lot

-- Disfruta tu trabajo (enjoy your work) (Bandera, Argentina)

View BobbyTheNewbie's profile

BobbyTheNewbie

8 posts in 429 days


#4 posted 10-25-2015 05:07 AM

Thank you!

-- Bobby, Texas

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