Building a Barn Door Using Reclaimed Barn Wood in a Steel Frame
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My Buddy Owns a salvage business down the HWY from me. This is where I get most of my reclaimed material. He’s got some cools stuff laying around out their. The barn wood for this project was salvaged from a barn in Blackburn Missouri
I jointed one edge straight so I could safely cut off the brown strip left behind from the batten boards which protected it from graying in the weather. Batten boards are typically installed on barns to cover the gap between the main boards to keep the wind and rain from blowing through the boards and into the barn.
Since the boards aren’t going to be sanded, I didn’t want to get pencil marks on the wood, so I put blue tape down so I would have a place to marker the locations of the dominos. I lined up the dominos to the back of the door. This way any unevenness that might occur will show up on the show side of the door adding to its distressed board look. Fun fact, most barnwood is only gray on one side. The brown side faces into the barn so it doesn’t get exposed to the weather, keeping its brown appearance.
The length of the door was much longer than any of my clamps, so I rigged up a reverse clamp to push against the final board to push it into place. The other end of the door is securely clamped to the table.
I welded flanges on the back of the frame to hold the wood in place. Even though the wood is distress and most likely the sparks will cool before leaving a mark on the wood. I took time to project the immediate area around the weld from the sparks, by covering the area with some scrap plywood. I also wetted the wood to prevent it from catching fire if I got my bead too hot.
This board is for the header above the door to bolt the track to. To mark the bolt locations I used a matching size drill bit, and spun it backwards to mark the locations. I then switched to the proper size bit to drill the pilot holes for the bolts at the drill press. I used the drill press instead of a hand held drill to ensure a straight hole
Finally I did a test fit of each bolt using a block of wood to hold the bolts straight as I drove them. If these bolts are a little off, the door will not roll smoothly on the track and not hang straight.
Tool List used in this video:
Just because a tool is listed, does not mean I endorse it. I have either liked it well enough to continue using it, or I can’t afford to buy something better. Tools are listed because “what tool is that” is one of the more frequently asked questions, and most links are affiliate links so thank you for your support.
• Delta Unisaw (my model is no longer made) – http://amzn.to/2ktT5Sl
• Domino 500 – http://amzn.to/2ktOH5K
• Assorted Dominos – http://amzn.to/2jqm2Nj
• Titebond CA Glue Medium – https://goo.gl/X3afqX
• TS75 EQ Track Saw Fetsool http://amzn.to/2kY0dnB
• Lincoln Electric MIG 180 Pro Welder http://amzn.to/2l5iW2M
• Craftsman Radial Arm Saw (my model is no longer made) http://amzn.to/2khZIr6
• Jet Parallel Clamps http://amzn.to/2kAVtmH
• Portable Hand Held band saw http://amzn.to/2kY76VH
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