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Custom Big Barn Door

  • December 13, 2018

Hoot 2k17
Hoot 2k17
Hoot 2k17
Hoot 2k17

Home made 36" wide barn door - design similar to Masonite's Cheyenne style door. 3/4" pine. Hand mortised handles. 3 layers glued and nailed. The final door is VERY beefy using 1x material. Total thickness is 2.25" after requiring some modifications to my barn door rail using a header.
The internal layer is 1x3 pine rails chamfered on all four profile edges. After done to all the 1x3's, a glue up was set up to adhere the internal panel together.
The outer layers are framed using 1x10" pine (archway cut by hand on a band saw) and bottom with 1x4" pine as the stiles. All parts were glue and pocket hole screwed using a Kreg jig.
After laying the outer frame over the internal panel, glue was applied and the frame clamped, then Brad nailed to secure. Process repeated on opposite side.
Small material can be substituted for the external frames or the internal frame to save having to modify the header to Stand off the barn door like I did.

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Comments (2)


  • Very impressive! We love seeing the progress from start to finish. Thanks for sharing!
    By RYOBI Nation, on December 17, 2018
    • Thank you! This was my first major project I undertook with no real guidance. I literally used my brains and it scared the living bejeepers out of me.

      Just goes to show you what a little bit of confidence and a plan in your head can accomplish!

      By Hoot 2k17, on January 5, 2019

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Custom Big Barn Door

by Hoot 2k17
Dec 13, 2018
Medium 17e81311 32ea 4aec b147 31c6d6cd5a65

Home made 36" wide barn door - design similar to Masonite's Cheyenne style door. 3/4" pine. Hand mortised handles. 3 layers glued and nailed. The final door is VERY beefy using 1x material. Total thickness is 2.25" after requiring some modifications to my barn door rail using a header. The internal layer is 1x3 pine rails chamfered on all four profile edges. After done to all the 1x3's, a glue up was set up to adhere the internal panel together. The outer layers are framed using 1x10" pine (archway cut by hand on a band saw) and bottom with 1x4" pine as the stiles. All parts were glue and pocket hole screwed using a Kreg jig. After laying the outer frame over the internal panel, glue was applied and the frame clamped, then Brad nailed to secure. Process repeated on opposite side. Small material can be substituted for the external frames or the internal frame to save having to modify the header to Stand off the barn door like I did.