DIY sliding pallet barndoor
DIY PALLET BARNDOOR
Once again, we’re back at the new office making things that we don’t want to spend the money on, and keeping a rustic feel. This time my we decided to create a barn door for the doorway between the front office and the conference room where the chevron table is at.
Material and Cuts
For the door materials we decided to raid the pallet stock yard we frequently visit. The findings there were quite good to include some 1x4s for the frame of the door. After it was all said and done we ended up with 30 pallet slats and and four 1×4 pieces. Next we picked up some more Dark Walnut and Cherry stains to go with the extra from the chevron table. Below you will find a link to the materials you need for the door.
For the handle 2 Galvanized Malleable Iron Floor Flange with Four Holes 2 90 Degree Elbow, 1/2″ 2 Galvanized Pipe Nipple, 1/2-Inch X 5-1/2-Inch 1 12″ Long Galvanized Steel Nipple Pipe Fitting with 1/2″ Nominal Size Diameter 1 Stops Rust Spray Paint, 12-Ounce, Flat Black
Cutting and sanding
Now that all of the wood and materials were together, it was time to cut and sand down the wood. Since our door frame was 80-inches by 36-inches not including the trim, I decided to go with a 44 inch by 80 inch door. After the frame was measure out I dry fit the pallet slats to ensure they weren’t too long or short for the frame and sanded them down quite a bit to eliminate the splinters.
Assembly of your barn door
Now that your door is cut, dry fit and sanded we can put it all together. Take two of your 1x4x80’s and run them parallel to each other about 44 inches apart. Now, place your pallet slats onto the 80’s securing them with wood glue and 1-inch galvanized nails.
After all of the slats are in place add the last two 80’s on the top and glue/nail them in place. Use clamps or heavy objects to secure the 80’s in place even more until the glue dries. Let the glue dry completely before moving on!
“Let the glue dry completely before moving on!”
Once the glue is dry you can now add the three 36 inch pieces to both sides of the door. You will place them on the top,middle and bottom to stabilize the door and finish out the frame. This will be completed the same way you did the 80’s.
ASSEMBLING AND PLACING THE HANDLE
For the handle we decided to go with an industrial feel so we decided to use galvanized pipe. To fit in with the colors we painted it black with rust-olium flat black paint.
HANGING THE DOOR
Now that your door is put together it’s time to hang it. I got the track for the door here. Once you get the track pieces together you need to measure out where you are putting it to ensure the height is right and there are studs in place to screw it to. If not don’t fret, you can screw a 1×4 into the studs and screw the slide into the 1×4.
Now you’re work is complete and you can stand back and bask in your job well done. If you try this project you should let us know how it came out and drop a picture in the comments.