Easy Barn Door Hardware
Barn doors are really on trend as you know but the hardware can be really expensive. Here is how you can make it for $30.
The wheels are made with plastic clothes line pulleys. These can be found at most home improvement stores for around $2. You will need two wheels per door.
You need just the wheels which means you must remove the plastic.
A-Using a wire snips, cut the plastic off
B-So the axle will be exposed
C-The axle must be cut. I used a Dremel but you can also use a hacksaw
D-If the entire axle isn’t cut entirely through, use a wire snip to cut it
E-Remove the wheel from the axle
F-In the center of the wheel, is a metal cylinder. Remove it by inserting a screwdriver in one side and pushing it out the other side.
G-You’re left with the wheel.
For the rods that are attached to the door,
A-Measure your length. I made my rods 8”.
B-Cut the bar using a circular saw with a grinding blade
C-Cut two bars of the same length
Add three holes to each bar; one where the wheel will be attached, two where the door will be attached. You will need a titanium coated drill bit to drill metal.
A-Clamp your bar to your work surface
B-Place the wheel near the top of the bar and mark where to drill the hole
C-Drill your first hole
D-You need two additional holes; measure and mark where the holes will be located
E-Measure the width of the bar and make you marks in the center of the bar
F-Drill the additional holes
Place everything on to a drop cloth and spray paint the pieces black.
For the wheel assembly, you will need:
wheel = 2
flat bar cut to size = 2
1/2” hex bolt = 4
1” hex bolt = 2
1/4” washer = 8
1/4” locking nut = 2
For the track assembly: (instructions below)
1” plastic spacer = 2
2 1/2” hex bolt = 2
1/4” washer = 4
1/4” nut = 2
Putting the wheels together:
A-For each wheel bar, you will need - one wheel, one 1” hex bolt, four 1/4” washers, one locking bolt.
B- Holding the 2 1/2” bolt, add one washer
C-place the bolt and washer into the top hole of the flat bar
D-add another washer
E-add the wheel
F-add a washer, then the locking nut
G-The finished wheel bar
You will need an additional metal flat bar to use as the track where the wheels will ride
A-Measure the cabinet where the door will be placed then transfer those measurements onto the flat bar. Drill two holes in the flat bar
B-Clamp the flat bar to the cabinet
C-Use a level to make sure the flat bar is level
D-Using the holes in the flat bar, drill holes in the cabinet
To attach the track:
A-a 2 1/2” hex bolt, B-Washer, C-flat bar, D-1” spacer, E-washer
Place into the hole and through the cabinet
Secure with a 1/4” nut
Attach the wheel bars to the door using 2, 1/2” hex screws
Hang the door by placing the wheels on the track.
No one will know that your barn door hardware only cost $30...unless you tell them.
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