DIY Modern Barn Door

Barn doors are the perfect option when you are short on space, but the problem is that they can be pretty pricey! See just how to design your very own DIY barn door on a budget with these easy step by step instructions! For more DIY projects be sure you get all our latest updates on Instagram @howwedo208! 

Why Barn Doors?

I am in love with barn doors! They are super functional and perfect when you are short on space, but as you know I love a very modern look rather than the rustic look of most barn doors. So recently I decided to take my own spin on barn doors to create a modern barn door at a super affordable price. The total cost of this project was about $300.00. The wood alone was $200 because lumber is crazy expensive right now. 

How to Get Started Making your Barn Door

First you will want to measure where your barn door will go. Measure both the width and the height. You also want to consider how much you want the door to overlap on the sides when closed. Most people choose about 2 inches on each side, but this is up to you. 

To come up with your final measurements you will take the width of the door opening and then add the overlap on them 2 times. 

So if your opening is 20 inches you will add 2 inches per side making your door width 24 inches. 

When it comes to the height you will only add the 2 inches once. So if the door height is 56 inches add 2 inches making it 58 inches. 

Getting Materials

You will want to head to your local hardware store to pick up the wood and other supplies for your project. I recommend having them cut your door size in the store to make your life easier! They usually do this for free or for a small charge. 

Supplies Needed for Barn Door

• ¾ inch thick MDF / Plywood 4ft x 8ft sheet. This is your main barn door that you will want to cut to the proper size that you determined in the measuring steps. Don’t forget to add those 2 inch overlaps. IMPORTANT TO NOTE: I trimmed my door for a more finished look. If you are doing this then you will want to subtract 1.5 inches in the width and the height to allow for the trim and for your door to work correctly. 
• 3.5 inch wide x 8 ft long Pine boards (if you are going to stain). If you are going to paint your door you can use a primed MDF. I used 10 of these to create the diagonal design on the front of the door. 
• For the trim grab 3 1x2x8 select pine boards. This will give the door a really nice finished look. 

• Wood Glue or adhesive (to glue on diagonal boards)
• Clamps (To help hold the boards in place)
• Finish Nails
• Wood Filler
• Nail Setter
• Orbital Sander or Sandpaper
• 3 sets of 2 paint sticks taped together (to use as spacers)
• Paint or stain
• Nail Gun and finish nails (optional)
• Barn Door Hardware (my Favorite)
• Door Knob I used

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Step By Step Guide to Building your DIY Barn Door

• First you will want to find the very middle of the door and mark it with a straight line. You will want to do this because you will be working on one half the door at a time. I found it really helpful to clamp a board on the middle line to help line up the boards and keep them all straight while working on the one side. 

• Once the middle is found, take your first pine/MDF board and cut the very edge at a 45 degree angle with your miter saw. ALL CUTS WILL BE AT A 45 DEGREE ANGLE. 
• After making your first 45 degree cut, lay it across the bottom of the door for your first diagonal cut. It is easiest to take a pencil and draw a line on the board so you know exactly where to cut it. My dad always taught me to use a straight edge to ensure the perfect line. 
• Once cut, glue it and then clamp it into place. If you are using nails and a nail gun then you can omit the clamps, but you still do need to use the adhesive glue. 
• Once the board is attached, place your spacers right next to it. The paint sticks taped together works fantastic! Lay your next board out and trace the edge of the door with your pencil. 
• Cut, glue, and nail down the board. Continue this process until one half the door is complete. 

• Remove the board that was marking the middle line, and then repeat the same process for the other half of the door. Be sure that you line up those diagonal pieces in the middle coming from each side.  

• Once all the diagonal pieces are attached it is time to add your trim (if desired.) Take your 1x2x8 boards and hold them along the door edge to measure and mark and cut them at a 45 degree angle. The mitered edges will meet up at the corners. You will want to attach them with glue and finish nails. I clamped mine to hold them in place. 

• If you have any nails that didn’t go down far enough into the wood and are sticking up a little bit, take your nail punch and use a hammer to punch them down so that the surface is flush and smooth.
• Fill all the nail holes and sand to make it smooth. If you’re planning to stain the door, be sure to use a wood filler that is the color of your wood.
• Paint or stain your door your favorite color and then it is time to hang it! It is easier to paint the sides of the MDF or pine prior to attaching. Just be sure that you let them dry really well before attaching them to the door. 

When it comes to hanging the door you want to make sure that you follow the barn door hardware hanging instructions. The overall thickness of the door turns out to be 1.5 inches. Be sure that you get a hardware kit to account for this and for 200 pounds to ensure that it properly holds the door safely. Add a door knob or pull, and you’re set!

There you have it! How to build a modern barn door on a budget! If you like video tutorials, you can watch me build this barn door here. Be sure to tag me on Instagram in your finished projects so I can see how awesome they turn out! #howwedoandyoucantoo

Love DIY Projects? Be sure to check out our DIY Shiplap Wall!