8' x 4' Cedar Barn door w/ Custom made hardware

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Project by Agentwusabi posted 02-23-2017 09:00 PM 678 views 2 times favorited 1 comment Add to Favorites Watch

I work out of a small one car garage that I have basically taken over with my woodworking projects, that being said… this door is 8 foot by 4 foot and took up so much room when assembling it. We both look at pinterest for ideas and inspiration and we both thought a barn door would be a perfect fit closing off the living room from the hallway. After some research I quickly found out that man are they proud of that hardware… so.. I bought a 20ft piece of 1 1/2” x 1/4” flat bar, a few needle bearings, shoulder bolts, lock nuts, and 2 pulleys to build my own track and hangars. I cut some 1” square tubing and welded them to the track and to mounting tabs so that I could attach the track to the wall. I bought some 2”x6” rough cedar and some tongue and groove cedar to make the door. I cut 3/4”x1” dado in the rails to slide the cedar boards in and also to accept the 3/4”x1” tenons on the stiles. I also painted some carriage bolts black and bolted the frame together through the joints to hold them tight and also looks better too. Lastly I needed something to stop the door from rolling over my speaker on the wall so I got an angle bracket, a long 1/4-20 hex head bolt,a lock nut, a spring and a spacer. I welded the spacer to the bracket after i cut the excess off then added the spring, bolt and nut, voila… a spring stop. We love this addition to the living room and when its movie time or the kids have friends over we can just slide the door closed.

1 comment so far

View Chapboat03's profile


15 posts in 1378 days

#1 posted 02-24-2017 02:38 PM

Great looking door! I like the idea of making your own hardware. Looked into pricing on it as well and thought it was over the edge too!
Great build.

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