Barn door hardware

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Forum topic by bonesbr549 posted 02-23-2015 07:19 PM 796 views 0 times favorited 5 replies Add to Favorites Watch
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1137 posts in 2485 days

02-23-2015 07:19 PM

In my future house I’ve been contemplating pocket doors or, barn door type doors for closets/bedrooms.

I prefer pocket doors like my grandma had. The wife loves the barn door hardware type. I was looking at the nice ones were looking at 500-1000 $$ a set.

Anybody out there ever made their own barn door roller/tube setups? Would love to see your designs?

-- Sooner or later Liberals run out of other people's money.

5 replies so far

View pjones46's profile


986 posts in 2061 days

#1 posted 02-24-2015 02:39 AM

I have not made my own tracks but have installed both. I hope she realizes that barn door type need wall space which can create furniture placement problems. So I’m +1 to your pocket door choice.

-- Respectfully, Paul

View ChuckC's profile


821 posts in 2353 days

#2 posted 02-24-2015 03:03 AM

Google around. A lot of people make barn door hardware from supplies at the hardware store. Check out YouTube as well.

View bruc101's profile


1075 posts in 2960 days

#3 posted 02-24-2015 03:04 AM

We have a bathroom in our upstairs guest bedroom that had pocket doors. 10 years later I was tearing out the wall to find out why one of the doors would not open correctly. Two days later wall closed up and no more pocket doors.

One of our friends has barn doors going into her den. We made the doors in our shop and she bought and installed the hardware herself. She ordered the hardware online.

The barn doors took her home to a new level and she gets many compliments on the doors.

-- Bruce Free Plans

View runswithscissors's profile


2127 posts in 1443 days

#4 posted 02-24-2015 05:45 AM

I have made my own as follows:

For tubing, use 1 1/2” square aluminum tubing. Rip a groove down the middle of one side of this with your TS. Make 2 passes to make the slot wide enough. This is your track.

For rollers, get 1” diameter ball bearings. Make a hanger out of 1/8” thick steel. Bore a shaft hole through this for an axle. The smallest bore you can get on the bearings is the best (maybe 3/8”?). You may have to use bushings to get down to a reasonable axle diameter—say, 5/16”. Since the sides of the track will box in the bearings, the axle doesn’t need to be headed on either end.

Weld the end of the 1/8” steel hanger to a piece of all-thread, 1/4 to 5/16” diameter. Make brackets for the top of the door, with a hole for the all-thread to go through. Drill a corresponding hole in the top of the door to receive the threaded rod (for adjustment). Nuts on the threaded rod enable vertical adjustment.

Hard to explain, so here’s a photo. Looks like I used 16 gauge steel for the bearing mount. A slot in the end of the all thread makes a weld here easy. Sorry I can’t show you the bearings, as they are up in the track tube. Obviously this sort of thing requires access to the inside of the wall.

Not elegant, but not expensive either. Mine happens to be double pocket doors. I’ll leave a removable panel over the door jamb for future adjustment.

I did a similar one for a barn door on a shed. I used steel angle, with brackets welded across the top for mounting the track. It has worked flawlessly for maybe 10 years.

-- I admit to being an adrenaline junky; fortunately, I'm very easily frightened

View runswithscissors's profile


2127 posts in 1443 days

#5 posted 02-25-2015 05:40 AM

Here’s another pocket door hanger I tried, but for some reason that I can’t remember, it didn’t work as well as the ball bearings. The little wheels were for sliding door hardware, I believe. That hanging strap is 1/8” thick, and the axle is 5/16”.

-- I admit to being an adrenaline junky; fortunately, I'm very easily frightened

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