How to Build Barn Doors

With the top half now installed, you have a completed set of barn doors. The doors should both close with an even reveal and be opened cleanly together or separately.

The next step is to install some door stop. Close both bottom and top doors so that they are flush with the outside trim. Go inside and measure from the top of the door opening to the floor on one side of the door, and cut a piece of 1x2 to that length for door stop. Install the 1x2 to the door jamb tight against the door using finish nails. This door stop will keep the door from over-extending the hinges if blown shut, and will cover the reveal around the door, keeping a majority of wind out.

Repeat the door stop on the opposite side of the door, followed by a piece of door stop across the top of the jamb between the two side pieces to complete the door stop.

Next, you can install the handles and latches of your choice, followed by your choice of finishing. In most cases one would likely choose to paint the barn doors, but you might choose to stain them. If painted, be sure to apply caulking to all joints and wood filler to all nail and screw holes, and do any sanding that you feel necessary. Because barn doors are typically rustic in nature, you may choose to bypass sanding altogether, but that is a matter of taste.

Note: If you are using your barn doors to keep animals, such as horses penned inside, you may want to keep in mind that some of these animals will try chewing on the top of the bottom door when the top is open and the bottom closed. You may want to choose a low-VOC paint for the finish if that is the case.