|Project by DBB||posted 03-22-2014 03:55 PM||1016 views||0 times favorited||4 comments|
This is a sliding barn door I built for friends to replace french doors between their living room and study. It is made from 100(ish) year old Wisconsin barn siding that was carefully power-washed, sanded and wire brushed to remove dirt and splinters but retain the wood’s character and as much patina as possible. Boards for the field had their edges trimmed straight, rounded over, then edge glued with biscuits. Tried to use as little glue as possible to minimize squeeze out since I couldn’t scrape or sand dried glue off the joints without ruining the patina. I had to glue each joint one at a time and the last photo shows my process to press the freshly glued joint down onto a flat surface (old door) to get it flat. Cross and diagonal boards on front and back were glued in place with polyurethane glue so it could expand into the gaps that still remained after I planed the contact surfaces as smooth as possible. No finish is applied, that is the raw wood. Track hardware is from Rustica Hardware and it is great, door slides smoothly and quietly. This was a challenge to get to hang straight and true since not one of the vintage boards was either straight or true, but I am happy with the end result and I think my friends are too.