These plans are by request, and illustrate how to build a sliding barn door for a sliding door console from 1x stock. The only complicated cuts are in making the x-brace itself, and that is only mildly complicated due to figuring out the proper angle. The rest of the boards are all straight cuts, so you should be able to complete this entire door in just a few hours.
Since the overall width of this door design is 16 1/8″, we’ve designed it from two planks from a 1×6, and two planks from a 1×4. All of these planks are going to be planed down to ensure they have straight edges so there are no gaps between the boards. You could probably get away with just three pieces of 1×6, with the boards planed down less,
If you have comments or question, please feel free to connect with us via the comments section below. We love the feedback! Also, don’t forget to check out our other free DIY project plans; and if you build anything from any of our plans we would love to see the result. Send us some images via our Submit Your Build page.
Materials
- 1 – 1×6 @ 6′
- 1 – 1×4 @ 6′
- 2 – 1z2 @ 6′
Tools
- Miter saw, circular saw, or table saw
- Nail gun
- Sander and sand paper
- Tape Measure
- Square
- Quick clamps
- Wood glue
- Wood filler
Step 1: Layout the planks
The first step in these plans is to cut and layout all of your planks that will make up the back of your door. Start with your two 1×4 pieces, and plane one edge so it is completely straight and square. Then rip the boards to a final width of 3 1/8″. Then repeat the planing and ripping process on your 1×6, ending with a final width of 5″.
There is no need to attach these together at this point, just lay them out and ensure the ends are all aligned.
Step 2: Add the upper and lower rails
With the planks laid out it’s time to add your upper and lower rails. Cut two pieces from a 1×2 to 16 1/8″ in length, leaving them at the stock 1 1/2″ width. Use wood glue and 1 1/4″ finish nails to attach one rail to each of the upper and lower ends of your planks. Use two nails in each end of each plank to ensure the planks are firmly attached to the rail.
Step 3: Add the stiles
Next cut two 23 1/2″ long boards from the 1×2 stock and add them as the stiles. Use wood glue and 1 1/4″ finish nails to secure them along the outer edges of the 1x4s.
Step 4: Add the long brace of the X
The next step in constructing your barn door is to add the long brace. Cut the long brace from a single 1×2 @27″ long. I recommend laying your board in position and then scribing lines on each end where it intersects with the rails. Once you have the lines scribed, set your miter saw blade to match the line and make the cuts.
Use wood glue and two finish nails per plank to secure the long brace in place.
Step 4: Finish the X
The final step of these x-brace barn door plans is to finish the X by adding the two short braces. This is going to be the same process as adding the long brace, except you need to cut out the section in the middle where the long brace passes through. Use wood glue and finish nails to attach the short braces to each plank they pass over.
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. After you have finished sanding the entire door it’s on to applying the paint or stain of your choice.
We hope you find these plans useful. Let us know if you have any questions, and don’t forget to submit your build if you create a barn door from these plans or any of our plans.
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