I really feel like this project was thrifty in that it was less than a hundred dollars (well, for the track, at least). And the amount of bang for our buck was HUGE. So, I wanted to make sure I wrote this post while the details are still fresh in my mind. So here goes...
We have a typical house for our subdivision - a large open door between our master bedroom and bathroom. It looks nice and all but we've never loved it. In fact, years ago I sewed curtains to separate the two areas. But they were a little too fussy and I took them down when I painted our bedroom a couple years ago. But now - we are THRILLED. Behold:
I personally love the doors open and they stay this way the majority of the time. However, they easily slide closed which the hubby appreciates when I am up at 5:15am every morning:
I am not going to tell you how I built the doors themselves because they are pretty darn easy to figure out and there are a ton of tutorials out there. In a nutshell, I built two doors and sandwiched them together. I only used three sizes of wood: 1x4s, 1x6s, and 1x8s. Here's a diagram:
I stained the doors black and gave them a coat of poly. My only advice with the doors - especially if you are building two doors - make sure they are square!!!
OK. Now that you've got your doors, you need to know how to hang them. There are actually quite a few barn door tracks you can purchase on Amazon that are priced very competitively. I can't vouch their quality, though. I can only show you what we did. And our DIY version - at less than $95 - was still cheaper than the tracks I found on Amazon! I followed this tutorial and it was great. I had a few questions so I'll show you what we did since it was a bit different.
First, and the hardest part, was finding the steel track. Home Depot only sells steel in 6' lengths. Since my doorway is so large I really needed about 9' of steel. (The width of the doorway doubled.) I didn't want to purchase two pieces of steel and put a seam in the middle of my track so I did a little investigation. (Investigation = googling) If you are looking for a steel track - Google steel supplier. Do not google steel fabricator. Anyway, Royal Metal Industries for the win!
I was able to purchase a 9.5' of 2" steel track (3/8" thick) for $14.20. Seriously. That's it! If I was thinking about it, I would have also purchased the straps for the door there as well.
Here is the Material list for the track:
(1) 1 x 4 x 10 common board to mount to the wall (cut to same length as steel track) $2.99
(1) Steel for the track - 3/8" thick and 2" wide. Double the size of your doorway. (My track is actually 6" longer than double the doorway.) $14.20
(2 per door) Steel straps to attach the wheels to the door. 18" long and 1/4" thick (We purchased 6' and cut it into 4 pieces with a hack saw) $13.99
(2 per door) 3" garage door pulleys $19.92
(7) 3/8" x 2" black pipe nipples (plumbing section) $9.24
(7) 3/8" x 5" lag screws $15.40
(4 per door = 8 for me) 5/16 x 2 1/2 hex bolts (connects bracket to doors) $1.92
(4 per door = 9 for me) 5/16 hex nuts $0.88
package of 5/16 cut washers $2.68
package of 3/8 cut washers $3.14
package of 3/8 lock washers $3.82
(2) 3x3 angle brackets (to stop door from rolling off the track) $5.14
(8) screws for the angle brackets $0.00 - I found them in my stash
I spray painted everything black because I just wanted all the hardware to just fade away.
Steps to Install:
1. Figure out how high you want the track and mount the 1x4 to the wall with screws.
- We have 1/2" clearance from the door to the floor.
- We have 1.5" clearance from the top of the door to the bottom of the track. Our track is centered on the 1x4. So basically, the bottom of our 1x4 is even with the top of the barn door.
- I used a stud finder and a long nail to find all my studs before I attached the 1x4 to the wall.
- I made sure to screw the 1x4 in at the top or bottom so I would be able to attach the lag screw for the steel track right in the middle.
The tape marked where my studs were in the walls.
2. Paint the 1x4 the same color as the wall.
3. Attach the "L" brackets at the ends.
4. Mark and drill all the 3/8" holes in the steel track for the lag screws. These holes will correspond to your wall studs. Ideally they would be 16" on-center but our house is all kinds of wonky and nothing is on-center. You will need special titanium drill bits for this process. If you have titanium bits it's not hard at all! (Make sure you drill the holes low enough on the steel track for the wheel to freely roll over the track. I just drilled in the middle of the steel and it was fine.)
5. Attach the steel track to the 1x4 at every stud. This is the order:
- Lag bolt
- Washer
- Track
- Pipe Nipple
We only used a 2" pipe nipple because it was enough clearance for our track to stick out far enough from the wall and still allow the door to roll freely. The pipe nipple is only there for spacing. It really does not go into the wood at all.
We pre-drilled holes and then used a hammer to get the lag screws started. Once it was into the stud the hubby used a wrench to tighten it all the way. Make sure your track is level - this is crucial!
Once you've got all your screws in the wall - you are good to go. Your track is done. Truly - it wasn't as hard as I expected.
6. Drill 3 holes in each 18" strap. A 3/8" hole 1.5" from the top, 5/16" hole in the middle, and a 5/16" hole 1.5" from the bottom. Ideally, they would all be 3/8" but my Home Depot was out of 3/8" x 2.5" hex bolts. Hence, I bought the 5/16" hex bolts instead. Again, you will need a titanium bit.
7. Now you need to install the wheels to the straps.
You attach the strap to the garage door pulley in this order:
- 3/8" hex bolt that came with the pulley
- flat washer
- 2" strap
- wheel pulley
- flat washer
- lock washer
- 3/8" nut
7. Now it's time to attach the straps to the doors. We set our door up on top of a book (to make sure we had a half inch clearance above the floor) underneath the track to figure out where to drill our holes. Once we had it figured it out, we laid the doors down on the ground and drilled the 5/16" holes to attach the straps to the doors. You basically attach them in the same order as above - just replace the wheel with the door. If everything is square and level, you should be able to use the same measurements for both doors.
8. Hang the door up on the track. Roll it around and CELEBRATE!!!
(This is what it looks like from the side.)
9. Attach the door handles.
That's it!! You're done!
And here is another picture of the finished product - to remind you how far we've come!
I hope this tutorial was helpful. Honestly, I thought this would be a lot harder than it was. It only took us a Saturday afternoon to get both doors hung up and we are thrilled. Let me know if you have any questions or if I left anything out. And if you do try this project, let me know how it goes!