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I’ll show you how to build a master bathroom sliding barn door that looks nice and costs less than $200. I must add that I’m no “woodworker,” by any means but I do like to try. For me, these projects have been a nice way to relieve some stress during the pandemic.
So it started with an “I was thinking…” from my wife. When she says that it usually means I have to either:
- move something
- paint something
- build something
- or buy something
In this case, it was to build something. We live in a split level house and the bathrooms are tiny. Our master bath feels even smaller when the door is open because it opens into the bathroom. The solution to our situation was to replace a tradition door with a barn door.
Figuring out a Plan to Build a Slidng Barn Door for My Master Bathroom
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I have never had to build a sliding barn door before. So I went to work figuring out how to do this, and I came across this video on YouTube. I based my door on the one in that video, but I modified mine by taking away the X pattern on the bottom half of the door.
Here is my list of materials I used for the barn door:
- Six 1 x 8 boards (8 feet) – cut five pieces to 84 inches and three pieces to 29 ¼ inches
- Two 1 x 4 boards (8 feet) – cut each to 84 inches long.
- 1 box of 1 ¼ Trim head Screws (Why? – Smaller head, leaves easy to fill holes and less chance of splitting the wood).
- Wood Glue
- Wood Filler
- Sanding Block (I used a random orbit sander as well).
- Stain (I used Weathered Gray)
- Poly-Urethane – I used oil based.
NOTE: Header Board. The barn door hardware is unlikely to line up with the studs on the wall, so I used another 1 x 6 board at 8 feet to cut to the length I wanted for my situation. I primed and painted this board the same color as the bedroom wall (some people stain it the same as the door) and attached it to the walls’ studs. This gave me a foundation to attach the door hardware.
(transparency: I am an Amazon Affiliate, but I bought these things before I joined that program. Regardless, that’s the first place I usually look anyway, as evidenced by the amount of cardboard I recycle each week).
Assemble the Sliding Barn Door
- Lay out all five longboards (1×8 cut to 84″) side by side lengthways.
- Attach the skinny longboards (1×4 cut to 84″) on top of each end board and flush with the edge using trim head screws (use wood glue on the underside).
- Next, lay the short 1×8 boards (cut to 29 ½”) across the top, middle, and bottom door. Attach with trim head screws (use wood glue on the underside).
- That’s it. Easy. You have just built a sliding barn door. You are going to have so much more space in a tiny master bathroom now. Hold on thought – you’re not done yet!
Prepping for color
- The trim head screws will sink into the wood and leave a hole, so use the wood filler in these holes and other gaps in the wood. I used Minwax Stainable Wood Filler from Amazon for $11.
- The door is now ready for sanding, and I used 80 grit on a random orbit sander. I finished with 150 grit sandpaper.
- Now it is time to apply the stain. The stain I used was Weathered Gray by Varathane leftover from another project. When applying a stain like this, use a rag made from an old T-shirt.
- Finally, I finished with 5 coats of oil-based PolyUrethane that I diluted down to 50/50 with mineral spirits. This allowed me to add a thin coat each time with a light hand sanding with 220 grit sandpaper between each dry coat (except the last coat).