Before designing barn door yourself, you should first ascertain the parts you will need to build barn doors. Commonly, you’d need lag bolts, carriage bolts, washers, hangers(for fixing door to track), rollers and steel track, these are all included if you purchase a sliding barn door hardware kit. The following steps will help you in building your sliding barn doors.
- Choose the place
Firstly, you need to determine where you want to install your barn door. You may want to set up door with existing opening. In that case, make sure that door is 2’’ wider and 1’’ taller than the opening. Alternatively, a new opening can be installed by either removing assembly of older door or removing drywall. In either case, it is recommended that you consult structural engineer proper equipment is in place from where the load of door is to be managed.
Selecting the wheel
Based upon the look of your home, you can select either rustic wheel with spokes featuring a traditional look, or you can go for wheel with hammered finish to give it a royal look. Wheels can be found for under $10.
- Gearing up the track
Track must be twice wider than the opening. It’s preferable to select one inch tension rod with bent ends to prevent feels from going off-track. Attach rod with 1 inch weld a foot apart. Arrange two angle irons such that they form U-shaped pattern. Set the depth of track to be at least 2’’ so that door fits tightly against the wall. Then drill holes at least one-third the total length of track, and choose carriage bolts that are at least 1.5 times smaller in diameter.
Then mark holes on wall placing welded iron on wall. Identify the location where door track will be fixed on wall. Calculate the distance from end of track to locations marked for holes and mark accordingly on welded iron. Then, drill holes ½’’ apart in angle iron.
- Prepare hangers
Fix the hangers to track using carriage bolts, and measure the distance between wheel and wall using horizontal leg whose length can calculated using the formula:
Horizontal leg = door thickness / 4 – mounting surface to wall
Tighten hangers against wheels using washers and screws.
- Installing the track
Place and fix the track ½’’ from the door, and similarly install guide track on floor ½’’ from bottom of door. Now, fix the track to door with help of measurements and marker taken before. Bolt angle iron to wall using 1’’ carriage bolts. Support the door with shim, and with help of another person fit wheels to track. Adjust the wheels, attach them to straps, which are then attached to doors. Drill two holes in straps at least ½’’ in diameter. Remove the shim, and ascertain door properly rolls.