I needed some doors for the wood storage cabinet I built and since the cabinets are huge (7ft), I knew I needed the doors to both function and serve as a statement art piece in my living room!
The first thing you'll want to do is break down the pallets. I wanted to have the nails show in my final design so I opted to maintain the entire length of the pallet boards. I felt I didn't do this correctly so I recommend referencing this YouTube video that will show you how to break them down a few different ways. One thing I would recommend is to get a corded reciprocating saw. I got the ones with batteries and the batteries kept dying within 10 minutes - I tried another saw, using different batteries, etc. I feel if I had a constant flow of energy, it might have saved me much more time!
To make these barn doors, I purchased quarter inch plywood and cut it down to the size of my doors (29" x 87"). I went ahead and stained the wood front and back with Varathane's Kona - I chose to go dark enough to match majority of the wood but not too dark (like black) since I think it would look off.
I determined the angle I needed to cut the wood and added some construction adhesive. I placed it along the guide and clamped it down, then nailed it into place with a nail gun. Once you have this first guide piece down, you don’t have to clamp the rest down unless you’re adding another guide piece. FYI - there are 2 guide pieces for each door!
I repeated the same for the other end and completed the rest of the design.
Once the design was complete, I notice the door was pretty flimsy so I flipped it over and glued on a 1x3 piece of wood on the sides, top, and center and screwed it into place.
I wanted the middle to have support so I added some pocket holes on the ends of the middle boards and screwed them into the longer 1x3's to have something that looks like this.
I took the door outside, face down and used a circular saw to remove the excess overhang.
After I trimmed down the doors, I added 3 coats of poly and let it sit overnight.
I wanted a little more to the doors so I added these garage door appliqués and handles according to the instructions they came with.
I didn’t quite know how to add these hinges, so I let my husband take it over.
I held the door while the cabinet was front face up and my husband made marks where the door and the cabinet will meet.
He made these holes with a fostner bit and screwed in the hinges and put the door back on the cabinet and screwed in the hinges. We referenced this YouTube video that was pretty good at explaining these hinges.I prayed and hoped the door wouldn’t fall off and it was good!
It did have this annoying squeaking so I took this knife hook thingie and shaved off the wood on the door that was pressing against the cabinet.. that pressing was making the annoying squeaking sound.
After I had the doors on I opted to put on hook and eye latches since I have curious little ones that will constantly open and close these doors if they had the chance to.
Now I have to say, these doors are not perfect BUT they get the job done. There is a gap between the door and the cabinet and I think that’s because I don’t have a magnet holding it in place and the doors are extra tall. I could be wrong but that’s my theory.
Also, there is a slight overhang on the door. Since it doesn’t cover the front completely like I anticipated (it’s because of the hinges, I think), there is overhang on the other side. Is it enough to bother me? Not at all but just keep this in mind when building yours!
Want to actually see me MAKE these doors? Watch this video :)
I also have a step by step photo tutorial on my blog with extra diagrams and tips if you're interested.
Here are the doors! I loooovvvveeee them!! I get so many compliments when I have company over and they're especially impressed when they find out I built them.