This is a fun little project that can add some cool aesthetics to your old shed, barn, or chicken coop. This method of construction is similar in building doors of any size for your outdoor or indoor projects. This little door is approximately 24″ square. Please make sure you watch the youtube video below for a fully comprehensive overview on how to build this small barn door.
A common 2″x4″ is used to make this particular door. Your door size will vary based on your rough opening. Measure your top and bottom lengths first and cut to fit the rough opening. As a rule of thumb, I like to keep a minimum of 1/4″ space around all edges when the door is assembled. This allows for a clean swing without dragging.
Observe the cleanliness of the pocket holes made by the Kreg Jig. This allows for you to make a very strong butt joint without having to use an expensive joiner. You must use the correct screws when using this method. Make sure you pick up a box of the 2-1/2″ Kreg Screws that are made for exterior use.
Prior to using the Kreg screws to attach the boards together. Make sure you use some wood glue on all of the butt joints for added strength. Once you’ve connected all of the joints you should end up with a cool looking 2×4 frame. Nice and square.
Pro Tip: Use a flat supported workbench and clamps when assembling to make sure everything is square and flush.
This plywood will rest inside of the framing and using an 18GA pneumatic nail gun, attach the plywood to the 2×6 trim pieces.
The final step in construction requires you to make the decorative “X” design. This look is often found on barn doors. Please watch my YouTube video to learn the tricks on how to do this easily.