How To Make a Barn Door

4 Materials
2 Days
Enable to remedy a unique design flaw, we came up with a clever solution. A barn door. As you can see in the picture, the laundry was built next to the kitchen, something which was aesthetically skewed. There was not enough space to put a regular door because if we made it to open inward, it would render the space too small, and if we made it to open outward, it would interfere with the refrigerator and the flow of the kitchen.
What a headache! As you can appreciate in the picture, there isn’t a lot of space between the refrigerator and the wall, so whatever we came up with had to be thin enough to fit between the two. We decided that a barn door could solve our issue. So, I am going to share the process with you.
We measured, designed and sketched out our door. And decided to construct it of wood and tempered glass. Purchased the wood and ordered the glass to our specifications.
We used a Router to form groves, tenons etc.
One side was glued together.
The glass was slid through the channels in the wood.
This is what it looked like. You can see that there is a groove on the bottom piece as well.
The last piece was placed and glued together making sure everything was fitted tight and squared.
Although there are many barn door hardware kits out on the market, we decided to build our own. We purchased Aluminum Flat Bar and bent it with heat and a hammer. To give it a rustic look, we used a Dremel tool to “scratch” the surface.
The door was sanded with the Ryobi sander and prepped with FrogTape for the painting process.
A coat of varnish was applied.
To see what we used for the rollers system click HERE
And this is the final result. Problem solved! Hope you liked it. Questions/Comments/Opinions are welcomed. See you next time.

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  2 questions
  • Suzie Suzie on May 27, 2018

    Did you buy or make the roller system that moves the door along the rail? If homemade, would love to see an explanation of the parts and how you put them together. Great job on the door!

  • Virginia Fraboni Virginia Fraboni on Jul 09, 2018


    What was the source of the tempered opaque glass?


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