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hey guys welcome back to bear mountain
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builds and today i'm going to show you
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how i built these beautiful matched
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grain barn doors
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[Music]
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hey guys welcome back to bear mountain
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builds i'm zach now i just finished
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remodeling this mud room here and i have
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a gaping hole for a closet right now so
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i need to put some doors on this so
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today i'm going to be building some
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match grain birch barn doors let's get
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started i have a piece of three quarter
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inch sanded plywood that's going to be
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the back side of my door and a piece of
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three quarter inch birch veneer plywood
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that's going to be the front side and
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i'm going to be laminating these two
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pieces together now let's keep going
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okay i got my two pieces of plywood all
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glued and clamped down i actually ended
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up using
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my old doors from the closet before
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which are made of like a particle board
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or something but they're super heavy so
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they're really great and also remember
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these because i have another project
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coming where i'm going to turn these two
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into a desk which is going to be great
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now just time to wait for this glue to
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dry up and we'll get this thing trimmed
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up
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all right i just finished taking all the
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clamps off and the two sheets are
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looking super good they're really flat
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thanks to the assembly table and they're
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really heavy which is great because i
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really want my doors to be heavy and
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solid
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now i'm moving on to using my circular
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saw to take just a sliver off on my four
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edges that way my two sheets of plywood
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are gonna be completely flush and square
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to each other it'll be great and then
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we're gonna bifurcate this bad boy let's
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keep going
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i flip the plywood so the veneer is face
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down that way the saw teeth are coming
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up into the veneer preventing blowout
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[Music]
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[Applause]
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[Music]
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so when i hang my doors i want the top
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of the doors to be 85 and a half inches
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from the floor one thing i got to keep
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in mind is i need to leave a half inch
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gap between the bottom of my door and my
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floor and i'm adding a piece of quarter
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inch trim on the bottom and the top of
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my door that means i have to cut my
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blanks out to 84.5 inches now let's keep
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going
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[Music]
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all right so i got the door blanks all
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cut out and i wanted to take a moment
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just to kind of show you what this match
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grain looks like on these two doors
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it looks really great and it's going to
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pop even more with poly and the best
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part is these are super easy to do all
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it is is just two pieces of plywood
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glued together and a cut right down the
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middle
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now we're going to be moving on to
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putting the trim on so i'm gonna be
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using some three inch maple baseboard
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it has a little bit of a ridge on this
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back side so i'm gonna run this through
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my planer to get this all flat i'll
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strip it down to the thickness of my
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door and then cut it to length and then
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glue and nail it in place now let's keep
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going
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[Music]
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i'm leaving my trim oversized then
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cutting it flush with a pull saw
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[Music]
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so
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[Music]
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i filled all my brad nail holes with
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wood filler and sanded them flush
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[Music]
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the edges of the trim are pretty sharp
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so i'm using a sanding block to round
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the edge
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all right so i have the trim all mounted
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up on both doors and i've sanded
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everything down to 240 grit that means
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i'm ready to put some poly on this thing
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so
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i did a little bit of testing over here
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so on the left i have a warm oil-based
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semi-gloss and on the right i have a
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water-based crystal clear saving glass
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and i did kind of a comparison between
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the two with my off cuts
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now the oil based is just a little bit
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too rich for me it it looks pretty good
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but i don't think it's going to match
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the room very well it's got a little bit
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of yellow in here so i'm not a huge fan
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of it but my water-based this keeps kind
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of the natural wood color but still
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brings out the grain really well so i
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think this is what i'm going to go with
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it looks super good can't wait to get
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this thing on
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now let's get this poly on these doors
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and hit the like button and subscribe
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let's keep going
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[Music]
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all right so i got one coat of poly done
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on this one i wanted to kind of show you
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guys
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how big of a difference poly makes it
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looks super good can't wait to get these
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both all pollied up so now i'm gonna let
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this dry then i'm gonna sand it with 240
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one more time and put my second and
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final coat on that and do the same over
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here let's keep going
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all right so while i have my doors
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drying i'll be moving on to building out
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my track so i have this maple board
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that's going to be the ledger board for
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the doors it's 10 feet right now so i'm
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going to cut this down to fit on my wall
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and then
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i have my track already put together
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like this first
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i have eight studs on my wall so i'm
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gonna pre-drill two holes for every stud
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on my ledger board with my countersunk
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bit
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and then i'm gonna lay my track down
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on top of my ledger board
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mark out all the hole locations and then
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i'll pre-drill those once i have my
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ledger board in place it'll be super
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easy to mount this thing up now let's
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keep going
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[Music]
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i realized the bit on my countersink was
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a bit too big for my screws so i ended
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up drilling the countersinks the
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old-fashioned way
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[Music]
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you might think i have terrible aim
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since i'm missing my circles completely
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but actually i realized my track wasn't
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centered originally so i remarked and
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then sanded those away after
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i figured out that if i use my door plus
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a quarter inch spacer i could set my
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ledger board on top in the correct spot
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and screw it into the wall
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[Music]
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in order to not strip out my lag screws
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i brought them to final torque by hand
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[Music]
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all right so i got my ledger board and
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my track all mounted up now usually
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people actually paint their ledger board
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the same color as their wall that way it
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kind of blends in with everything and
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you don't really see it as much but
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i kind of like this brushed metal
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with the maple board i think it looks
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pretty cool
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so i'm gonna stick with it until i get
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my doors hung up there and i'll make my
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final decision then but i think it's
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looking pretty sweet right now
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now i'm gonna head back over to the shop
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and attach my hangers to the doors and
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we'll get these things hung up so my
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hardware does give dimensions for the
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hole positions right here
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i went ahead already and made a template
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for my holes for the hanger so all i
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have to do is take this
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put it up into the corner right here and
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then i have a backer piece that's going
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to go on the opposite side that's just
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going to prevent blowout for when i'm
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doing my drilling so i'll clamp this all
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in place drill these holes and then
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slap these bad boys on now let's keep
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going
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[Music]
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so
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[Music]
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all right so i just got done doing the
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test fit for both these doors and i did
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a few fine adjustments so they just
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matched well and they rolled really well
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but they're all good to go so now i just
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have two last things to do so one i have
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this little bumper thing that goes on
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the top of the door and that just makes
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it so the doors can't pop off vertically
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and then the other thing is i have to
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route out a channel
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that's a quarter inch wide along the
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bottom of both these doors
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to fit this through that just locks into
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the ground so that way they don't swing
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back and forth so when i put that bottom
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trim on i kind of forgot that i was
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going to be routing out a channel there
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so there's a bunch of brad nails right
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through the middle of it but i still got
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to rot out that channel so there might
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be some fireworks so i'll try to get a
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good angle now let's keep going
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[Music]
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all right it's time to put the final
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piece on these doors
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the door handles now here's what i'm
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doing
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now here's what i'm doing
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i've repurposed my old template i used
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for my hangers to now have holes for my
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door handles i made a spacer that's 39
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inches long to set the height for my
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door handles and then these holes are
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two inches in
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now one thing to note is these are my
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screws for the door handles
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and they are the exact same length as
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the thickness of my door
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which means i'm gonna have to put a
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quarter inch bore on the backside just
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so these can fit all the way up in there
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and then get into my handles
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[Music]
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so
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[Music]
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and with that these doors are done
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[Music]
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these barn doors are super simple to
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make and they turned out great it really
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is amazing what you can do with a single
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piece of birch plywood now as always hit
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the subscribe button so you can stay up
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to date on all my videos and if you
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enjoyed this video hit the like button
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for me it helps me out a ton and leave a
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comment your comments are amazing and i
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love reading them they're super helpful
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now thanks for watching and i'll see you
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next time17618
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