How to Build Barn Doors – Free Woodworking Plans
If you have a shed or a barn, a well-built set of Dutch-style barn doors can provide not only unique functionality, but are quite attractive and very durable. Barn doors are traditionally sheathed with tongue-and-groove stock, but this set of plans takes a little bit of a different approach: using T-111 siding for the sheathing.
These plans are relatively simple to build, provided you have access to a table saw, miter saw, circular saw, a couple of pneumatic nailers and a drill. One could get by without the pneumatic nailers, but they make the job go by much quicker, particularly if you have a few of these doors to build.
One thing you’ll definitely need to keep in mind is that these doors are relatively heavy. The plans are designed for a door opening that is 4070 (4-feet wide by 7-feet tall), and the lower half weighs well over 50 pounds, so make sure that the hinges you choose to employ will handle the weight. The bottom half of the door is 4-feet tall, while the upper half is 3-feet tall, so the upper half is definitely lighter, but that’s not a lot of concession when you have to hoist it up and in place to position the hinges. While one person can easily build the doors, you’ll want a couple of extra sets of hands for positioning them.
The benefit of that weight is that these doors are stout enough to be used in a horse barn, where the horses like to lean against the door with their necks to try and get to whatever they see outside. When hinged properly, these barn doors will be durable enough to stand up to such abuse and last for years.
Download the Free Woodworking Plans to build your own barn doors (PDF).
Difficulty Level
- Woodworking: Moderate
- Finishing: Paint
Time to Complete
- 6-8 Hours (woodworking) – 3-4 (finishing)
Recommended Tools
- Table Saw
- Circular Saw
- Compound Miter Saw
- Cordless Drill or Power Drill
- Random Orbital Sander
- Tape Measure
- Pneumatic stapler
- Pneumatic framing nailer
- Pneumatic finishing nailer
- Pencil
- Countersink Pilot Hole Drill Bit
- Woodworking Clamps
- Layout square or framing square
- Chalk Line
Materials Needed
- 6 – 2×6 x 6′
- 1 – 4×8 sheet of 3/4″ T-111 siding
- 4 – 2×4 x 8′
- 6 – 1×4 x 8′
- 4 – Heavy, barn-style strap hinges
- 1-1/4″ treated deck screws
- 2″ treated deck screws
- Handles and Latches of choice
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