I built a barn door for Elisabeth and Yannick from Bourget ON. Their barn used to have a small window, so they wanted to open it up more. The door measures 79 1/2" tall by 41 3/4" wide, and is 2 3/4" thick! It's made of 1"x8" and 1"x12" rough shiplap pine boards from Home Depot.
I started by building the frame using pocket hole joinery. I cut all the boards to size and sanded them to 80 grid. I then assembled the boards, dry-fit everything, made some adjustments, then glued, stapled and screwed all the pieces together. I also sealed every crack with silicone.
I added an 18” x 23” sliding window with a screen. The window is from Outdoor Hardware Supply out of Dover, Pennsylvania. The heavy duty hinges are from System Equine out of Rockwood Ontario.
The door weighs north of 200 lbs., very solid. Elisabeth and Yannick will stain the door in the spring, and Yannick will add a small concrete pad at the door's entry.
It turned out awesome!
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