And thar she blows….
If you are new to the scene, you didn’t read about my original door that hung here that was completely laughable. It was all sorts of wrong.
And if the barn needs painting, you paint it. If the barn door needs custom built, you learn painfully how to use a Kreg Jig. That’s a saying by the way. In a very small circle of people….namely, you and me. Anyhoo…let’s get back on track….this barn door track 🙂 So the original door that hung here had issues and we had to remove it so the solution was a barn door track. We installed the track and it is awesome….super smooth, doesn’t make a noise, hangs perfectly, looks legit. The door itself was too small and looked ridiculous. We actually went ‘door shopping’ where we called around and stopped in at a few local stores to see if we could hunt down a door that was the style of the old one but larger. We hoped that for around $100 we could just buy one and cut it to fit. No such luck. So that’s when I put on my big girl panties (that also has an attached tool belt) and decided to build one myself.
The plan was fairly simple. It required 2×6’s for the outer frame of the door and then I would pocket hole the inside 1×6’s. I was going for a planked look that was simple and clean and more contemporary than most barn doors. Usually on Pinterest, anything that hangs on a track is really really rustic looking…and that just would not fit the look here. That’s why we went with something more sleek.
And so I got to measuring… (I took this photo with my third hand…I highly recommend it for all moms out there!)
and line drawing…
and cutting. Note that this part of the project was roughly two weeks after LJ was born and my hair had not started falling out yet. All those whispie pieces….they were growing in from when I had Weston….and now are gone. plus some.
Once the frame was done, I started reading the instructions to the mini Kreg Jig I own. I actually got it for free at Haven last year and this is one of the first times I even considered using it. Now we are both addicted (as soon as I mastered it, I showed Jeremy who is now a Kreg Jig fool…seriously, I wanted to rename him Craig.)
The inner panels were
As you can see….I had issues. First, I didn’t double check the depth on the jig so I was drilling pocket holes that weren’t shallow enough. Then I realized later that I should have done some holes to the sides of the door. ::brainexploding::
At one point, one of our neighbors came over and I showed her how to use a drill. It was a blast to build with someone. #girlpower
I had 1.4 million pocket holes to fill, so I whipped out this 3M wood filler. I like that you can squeeze it into the holes instead of digging it out of a tub. I smoothed it with an old debit card…because ya know, I hoard those.
Some of the holes can be filled with these little wood pieces. I wouldn’t recommend using them if they stick out beyond the surface of the wood. I even tried a trick that you use a little tool to buzz off the excess but mine still looked weird. If it sticks out beyond the surface of the wood, I think removing it and just using filler is the way to go.
Oh and did I mention the filler? Yeah…the first round of it wasn’t enough and after sanding it, I was meticulous to go around and refill any low or crazy divots.
After it was all said and done, I had my mistakes filled, my legit pocket holes also filled and they were ready to be sanded.
I had to lay other 1×6 boards under the inner paneled part of the door in order to sand but I needed to put a lot of pressure on the boards to get them to be really smooth. I like to start with a high grit (60) and move to 120 and then to a 220 or 320 sandpaper for the last round. It gets it really smooth that way.
I primed with Kilz Premium on this door – both front and back and I did about two coats of primer to block the raw wood knots from bleed through. I know some folks put filler on those areas to block them even more. Then it took two coats of semi-gloss paint in bright white (just untinted paint) to match the trim work.
After that, I took the door inside and lined it up with the doorway to make sure I could get the hardware in the right spot. Holes were marked and then drilled. (it looks like I am drilling into the door that is laying on the floor…but there were 2×4’s under there so that I didn’t damage our floor)
Then I attached the hardware with a couple wrenches.
The final steps were to fill the gaps between the boards with caulk. I also did another coat of paint over the entire thing. Caulk can change color or hold dust differently than painted spots so it’s not a bad idea to do an extra coat over it.
See that magic?! I love caulk. Don’t read that out loud.
All I had to do was hang it and it was ready for action.
When it’s open, it slides all the way to the left and there is a little bit leftover that you can see from the laundry room angle. It doesn’t bother me at all because it needed to be that big for complete coverage when it’s closed. It doesn’t get in the way at all because the washer bumps out that far anyway.
And when it is closed, (and it is usually never closed when I am in here…I mean…it doesn’t have a lock so whats the point of hiding from the kids in here?!) you can see the flat side of the panels.
I closed it all the way so that you can see how big it is and how it is no longer too small for blocking the gaps around the door (like the previous door). During the day, light can still shine around it but that is fine by me…it’s like the crack you see under a regular door. Oh that is another pro of using a heavy duty hardware piece vs. doing one of those homemade sliding doors. With homemade sliding doors, usually there is a eye hook on top that goes on a piece of pipe (that could cause metal-on-metal mating noises) and then on the bottom is casters…which would mean that your door has to be a bit higher which would allow light, dirt, small animals through. It’s definitely cheaper to DIY these but sometimes it is better to just shell out the $40 extra bucks.
And this is how it is 99% of the time. Open and glorious. I am really proud of how it turned out. Even if it does have two little Weston-induced-dents on the top. I will fix them in time. A little Bondo and paint should do the trick.
That’s the story about how I built a door. Still undecided on hardware. What have y’all been building lately? Anyone else getting Kreg Jiggy with it?