I have wanted to build a modern barn door somewhere in my home. In my basement I have only one door that leads to the bathroom. This was a perfect candidate as I would not have to compete or consider remodelling other doors. See the detailed plans for a step-by-step tutorial
What you need for your modern barn door
- Painters tape
- Table saw
- Mitre saw
- A pin nailer. I used a Ryobi 23 gauge Pin nailer
- 1.5inch pin nails
- Two pieces of 4 x 4 hardboard in 1/4 inch thickness. If you can find a 4×8, snag that!
- primer. I use Sherwin-Williams wood and wall primer
- Paint. I used Sherwin-Williams urbane bronze 7048 in the Emerald line
- Paint brushes and small 2-3” rollers
For the detailed cut list including measurements and angles of each piece, see the building plans
Let’s get building your modern barn door
1. Tape out your modern barn door design. Trust me this is really important for you to help you visualize. If you like the design I picked, you can easily build this door with the building plans
2. Cut your hard board down to size. Unfortunately I had two pieces of 4 x 4. When measuring, take care along the edges of the door depending on which way your door opens. You’ll need to account for the thickness or the door trim. If you can get 1 piece of 8×4 ft, snag it!
3. Remove the handle on your door. Lean your board against the door and mark out a circle for the handle. Using a jigsaw cut the circle for the handle. If your door hinges creep on to the door, you may need to cut those out as well.
4. Using the pin nailer, nail the boards onto the door. Account for the edges so your door opens and closes easily. I used a few books stacked at the bottom of the door to prop my door up.
5. With the leftover cardboard, cut strips that are 1.75 inches wide using the tablesaw. You can use a circular saw, but it will take you a very long time. Many hardware stores will cut it for free or a nominal cost
6. Now the fun part start cutting pieces for your design. For the detailed cut list, see the building plans
7. Use a piece of wood as your spacer between every single piece of molding. This will ensure that all your spaces are even. Mine was about ¼ inch thick. You will need to place the spacer between every board, before nailing it on.
8. You need to measure each piece cut it, and then nail it. You can find the full cut list in the building plans. Then measure the next piece, and cut it. Do not make all your cuts at once. I know this is tedious but the beauty is in the perfection. (I started with wood glue but realize this was unnecessary). This barn door is going to look perfect!
10. You’re almost to the finish line. Apply wood filler at any seam where you patched together the hardboard as your flat panel. Use a criss / cross motion and don’t leave too much excess on the door. Try to get a clean seam. Use p220 sandpaper to smooth it out. A second coat may be necessary.
11. Apply primer. I used Sherwin-Williams wood and wall primer
12. I then used two coats of urban bronze 7048 by Sherwin-Williams for this modern barn door. The colour is just gorgeous
Ready to start building this modern barn door? Purchase the detailed building plans here
I would love to know if you did this project. Follow me on Instagram @hanashappyhome, and share it with me!