Since Tucker’s room was originally a master closet it was long and narrow. With his bedroom door on the long side of the room it took up a good part of the narrow space when open. Of course with a boy’s bedroom it seems like the door is always open! In order to give Tucker room to play and get the door out of the way we decided to give him a pallet sliding barn door. I had some pallets in the garage leftover from buying wood pellets for our stove so I decided to try and create a pallet sliding barn door. I think it turned out great! It brings some rustic to the room, frees up space, and looks really cool!!
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What you need:
Finish nails and nailer or hammer
3 wood pallets
Sliding barn door hardware kit
In general sliding barn door hardware seems really expensive. On most sites it can run upwards of $200 for a hardware set. I found one on Amazon for about $90 including shipping. It is really high quality and I would recommend it if you are in the market:
Here’s how I put the door together:
You have to first dismantle the pallets to utilize the wood. Here’s where the hammer and flat crowbar come in. You have to take care with removing the boards. Pallets are made to not come apart so these nails and board are tough to pry up without cracking every board you pry up. In order to create a door that is 80 inches tall you probably will need as much board as you can salvage. It’s ok if they have minor splits in them or knotholes, etc…it just gives the door that much more character.
Hopefully you’ll have better luck at removing the boards than I did. I’m actually a very patient man normally. Tara always complains that I’m too patient with most things…except for diy projects ;). I got impatient with prying the boards off of the pallets so I used my circular saw to slice down either side of the pallet.
Then all I had to pry off was the middle part of the boards and was left with a pile of boards from 35″ to 40″. So the door would have to be 2 sections of boards. I started by making a top, bottom, and center rails for the door. I wanted to be able to slide the vertical boards into the rails so I notched the rails appropriately. Each rail was just 2 of the pallet boards glued and nailed together with notches in them to receive the vertical boards.
Once the horizontal rails were set I cut all the remaining boards to 2 sizes. All the longer ones I cut to 37.5 inches and the shorter ones were 35 inches. Once this was done it was a simple matter of sliding the vertical boards into the horizontal rails while glueing them and fastening with my finish nailer. Here’s the bottom half done.
Once it was all together and the glue had dried I just gave it a good sanding…making sure all the edges were nice and smooth so the kids won’t get any splinters when opening it. Once I got the hardware installed above the door I realized the door was a little short so I simply tacked on a little to the bottom and covered the joining seam with a thin piece of pallet board. I wouldn’t worry too much about adjustments like this. After all it’s a barn door…it’s not supposed to be perfect.
I cut and added a few pieces of pallet wood to the pallet sliding barn door for the roller bars to fasten to.
Don’t forget to Pin our Pallet Sliding Barn Door!
If you really like Pallet Projects you might want to check out our other Pallet Projects!
Or how we changed the doorway in our son’s bedroom and added a transom window!