Looking to build your own barn door? This Double X barn door is actually easier to build than you might believe. Due to using lap joints for the frame, the joinery is simple and there are no complicated cuts. You also don’t need any specials tools or jigs outside of basic woodworking tools.
Materials
- 6 – 1×6 @ 8′
- 2 – 1×3 @ 8′
- 6 – 1×6 @ 8′ Tongue & Groove beadboard planks
Tools
- Miter saw and circular saw (or table saw)
- Nail gun
- Sander and sand paper
- Tape Measure
- Square
- Quick clamps
- Wood glue
- Wood filler
Step 1: Layout the front frame
The front of the frame is going to be made entirely of stock 1×6 materials. The two stiles will be cut to a full 83″, while the rails are cut to 31″.
There is no need to attach these together at this point, just lay them out and ensure the frame is square.
Step 2: Cut and lay out the back frame
The back frame is also going to be made out of 1×6 material, but for these we are going to be ripping 1″ off of each board. This brings the width of each of these boards to 4 1/2″. Now cut two 74″ stiles and two 42″ rails.
Lay these out on top of the face frame, making certain the outside edges are all flush. This will create the lap joints that provide stability to your double x barn door. Now glue all of the back frame boards to the face frame boards, and use clamps to hold the boards tight and in place while the glue dries.
Step 3: Add the beadboard planks
Since the beadboard planks we are using wind up being 5 1/2″ in width when they are joined via the tongue and groove, we shouldn’t cut any of them width-wise. We only need to cut all six of them down to 74″ in length.
Once you have them all cut, join them together using the tongue and groove. Do not glue them together. Now glue the sides of first and last board, as well as the ends of all boards, to the 1″ recess on the back frame. Use 1 1/4″ finish nails to hold them in place.
Step 4: Build your Xs
Now it is on to building the Xs of your double X barn door. Start by finding and marking the exact center of your stiles, then cutting two 47 1/2″ pieces of 1×3. Lay these pieces out diagonally so that they meet at the center line. Now mark the angles where the pieces meet and cross the stiles and rails. Cut the miters and glue and finish nail the long X pieces in place.
Now, follow the same procedure for the shorter Xs, using four 24″ pieces of 1×3
Step 5: Sand and finish
Now that your construction is finished, it’s time to sand and finish. Use wood filler to fill any nail holes, then sand using 120 grit followed by 180 grit sandpaper.
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