Secondary track Roller.

Recessed into Oak. No need to paint because always will be hidden behind door. Chipped our with 1" wood chisel.



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Secondary Track

The door swing a bit so we are installing a secondary track. Found this track at Lowes for $11.


Then cut and ripped the track with a reciprocating saw and painted black to look like this.



Will screw into the wall just above the trim to have a second track that should keep the door perfectly in place.
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Locking in heading board

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Pocket handle

This handle from the other side of an old closet door can go in the back of the door... So people are not locked in the basement.



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Black spray paint...

The last time I used black spray paint it was to paint my 1973 dodge duster black! Now using to Change Zinc colored hardware to black...


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Sawsall hardware to size

The bolts that came with the hanging clamps are too long for the width of our door, so I decided to cut them to size.



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Coat 1 complete

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Step 2: Sanding

Starting sanding: 100,150,220,320 grit...



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Cutting the box rail

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Connecting 7 of 10

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The Harbor Freight self-centering doweling jig is horrible at creating dowels in the center! I could do a better job with my eyeballs only! Fortunately, it is consistently horrible, which should mean that the dowels line up, which in my case will work fine! Nothing like cheap harbor freight tools for the Do-it-Yourself-er.

First 3 boards

Here are the first 3 boards. We'll see if the self centering jig helps!



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Self centering Jig

To help center the holes, picked up this self centering jig at Harbor Freight. The plastic thingy did not work well enough. :(


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Helper

Picked up a helper!



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Drilling

Here is a picture of drilling the holes!




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Aligned dowel holes

I wanted to be sure all of the dowel holes lined up so built this contraption out of some scrap plastic from an old combination square. Filed one edge so the plastic would hang on the edge of each board. Drilled a 1/4 hole where each dowel hole would be screwed in. Hope it works!



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Mark drill holes

To try and make the drilled holes for dowels align perfectly, I stacked the boards, aligned one slide with a straight board, and used the combination square to mark vertical lines 1' apart. With 6" clearance from top and bottom this is 108 holes, 54 dowels... Wow. That's seems like a lot!



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Tools for Step 1

Here are the tools collected for Step 1:
Hammer
Square
Gorilla wood Glue
Drill
1/4 drill bit
Tape ( to mark depth)
Dowels



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Step 1: Connect 1x4 7' Planks

The first step is to connect all of the 1x4 planks to make a solid door. At first I was just going to screw 1-1/4 inch drywall screws into the back and cross members, but the oak wood is so nice I did not want to ruin it with a bunch of screw holes. The very helpful guy at Home Depot suggested that I use wood dowels and that is what I will do!



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Box Rail

Here is the Box Rail kit we will use to hang the Door. Interior Barn door hardware is crazy expensive online ($500-$1000)! We saw others use this and thought it was a good idea... We picked up for $100 at Tractor supply Company. We will paint black and have to cut the box rail to size... The smallest they sell is 8' and we only need 6' for a standard door opening.


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Oak Barn Door

Here is the basic layout of our door! We selected oak because it should warp less than pine or poplar and should look good when stained. The vertical boards are: 10 1x4s that are 7 foot long, the cross bar is 1x6 7', and the top and bottom boards are 1x8, 3'. We spent an hour laying this out at Home Depot last night and finally settled on this layout!


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Space

Here is the space where the barn door will go. Hopefully you can see how a swing door will almost run into the kitchen cabinets and make things crowded. The barn door is suppose to eliminate this. We have 4 kids running around and need to reduce obstructions!


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Barn door in the Kitchen? Um. Why?

Why would you put a barn door in the kitchen? Good question! The idea is that the swinging of the door takes up a lot of space. By having the door slide, it does not get in the way. When we explained the idea to Garrett, his response was: "No, that is not going to look good." Hopefully we can change his mind! Here are a few examples of how this can look: http://extremehowto.com/designing-building-and-installing-an-interior-barn-door/ http://www.reclaimedlumberproducts.com/sliding-wood-doors http://www.curbly.com/users/capreek/posts/9906-diy-sliding-barn-door-from-salvaged-wood

Barn Door Installation

Today is the day for the interior barn door installation in our kitchen! I will BLOG the project here to see how far I get in the next 12 hours or so...