DIY: Pallet Sliding Barn Door

Come check out the Pallet Barn Door We Made using only 2 Pallets!

Updated: 08/2019

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!!

Come check out the Sliding Pallet Barn Door We Made using only 2 Pallets! It brings so much character to our farmhouse without taking up any floor space! #palletprojects #palletdoor https://lehmanlane.net

DIY – Pallet Sliding Barn Door

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What you need:

Hammer
Flat Crowbar
Wood Glue
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:

TCBunny Sliding Door Hardware Closet Set Antique Style (Black)

You can find A LOT of different sliding barn door hardware on Amazon,

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.

IMG_0757.2015-01-11_213647

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.

DIY Pallet Sliding Barn Door

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.

Pallet Sliding Barn Door - Lehman lane
Pallet Sliding Barn Door - Lehman lane
Pallet Sliding Barn Door - Lehman Lane

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.

Pallet Sliding Barn Door - Lehman Lane

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.

Pallet Sliding Barn Door - Lehman Lane

I cut and added a few pieces of pallet wood to the pallet sliding barn door for the roller bars to fasten to.

Come check out the Pallet Barn Door We Made using only 2 Pallets!

We couldn’t be happier with how our DIY Sliding Pallet Barn door turned out!!!

Come check out the Pallet Barn Door We Made using only 2 Pallets!

Come check out the Pallet Barn Door We Made using only 2 Pallets!

It is the perfect sliding door to separate our boys rooms. To see more of Tucker’s room, you can check that out here.

From Closet to Boys Bedroom - Final Reveal - #boysbedroom https://lehmanlane.net
From Closet to Boys Bedroom
Come check out the Sliding Pallet Barn Door We Made using only 2 Pallets! It brings so much character to our farmhouse without taking up any floor space! #palletprojects #palletdoor https://lehmanlane.net

If you really like Pallet Projects you might want to check out our other Pallet Projects!

10 Pallet Furniture Projects to Try

10 Pallet Furniture Projects to Build to bring Farmhouse Character to your home for FREE #palletprojects #farmhousestyle https://lehmanlane.net

DIY – Pallet Desk

DIY Pallet Desk - how to make a simple built in double pallet desk
DIY Pallet Desk – Lehman lane

DIY – Pallet Towel Rack

DIY Pallet Towel Rack - sharing a step by step tutorial for how we created 2 different DIY pallet towel racks for our boys bathroom #towelrack #palletprojects http://lehmanlane.net

 Or how we changed the doorway in our son’s bedroom and added a transom window!

4 DIY House Projects to GiveYour Home More Farmhouse Character - Changing the Doorway and Adding a Transom Window
DIY Transom Window & Doorway

DIY Angled Door

How to Build an Angled Door

DIY Pallet Shelf for Flowers

DIY Wood Pallet Shelf for Flowers - Create & Share Challenge

For More DIY Projects from Lehman lane, follow along our DIY Projects Board on Pinterest!

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53 thoughts on “DIY: Pallet Sliding Barn Door

  1. Great door. I like how you joined the slats together. How did you manage to notch the center board so well on either side. Did you use a table saw and then clean it up with a chisel? Also, have you run into any warping issues.
    Thanks,
    Barry
    Northern NJ

    1. Hi Barry, I notched the center boards of the pallet barn door just like the end boards. Just to be clear it’s 2 pallet boards notched on both sides of each board and then glued and nailed together to create the full notch to receive the vertical boards. No, we have not had any warping issues with the door. Let me know if you have any other questions. Thanks

  2. What a great job! It looks amazing!!
    How creative! glad to hear about the barn hardware from Amazon….if I ever get the opportunity….
    Nancy
    wildoakdesigns.blogspot.com

    1. Rita, Thank you for stopping by and for your sweet comments about our pallet barn door. It’s definitely not as heavy as it would be if it was made of oak slats but it is still pretty heavy:). The hardware makes it very easy to slide so the weight doesn’t really matter. Take care, Tara

  3. Great job. Well done ! Pity i cant see from a closer look how it is notched to the door and if its smooth when it closes and opens. It looks fantastic though. Bravo for the inisheative ..( du excuse my poor english ..)

  4. What a cool door Tara and the rustic feel is perfect for a boy’s room! Featured at Be Inspired this morning. Thanks so much for sharing!

  5. This is a gorgeous door! Thank you for taking the time to show step by step directions! In addition, it was kind of you to include the hardware information. Inspiring site!!

  6. Love this! Did you power wash or sand the boards? I’m curious how and if your supposed to clean them or if your better off leaving them in their natural state. Thank you

    1. Thanks so much for stopping by Sara! My husband sanded down the pallet boards A LOT before adding them to the boys bedroom:) We didn’t want to risk any splinters when the boys were sliding their door back and forth!

  7. Love the barn door. We are getting ready to put one on our pantry. Since it has been almost a year I wanted to check in and see how the hardware is holding up? Is it decent quality? We are trying to decide on what hardware to purchase.

    1. No problems with the door swinging out from the wall. The barn door kit comes with a door guide to keep the door close to the wall. Thanks so much for commenting Janice!

  8. I’m wanting to do a bedroom and a bathroom sliding door in my mobile home the thing I’m concerned about is the weight mobile home walls aren’t as strong as house walls I think I would have to make a free standing frame of some kind so the weight will be secret from the wall

    1. Thanks so much for stopping by David. I don’t have any wisdom on construction in mobile homes so I don’t want to tell you the wrong thing :). I would say that our pallet door is probably a similar weight to any solid wood door.

  9. I love your work!! Can you please tell me what saw you used for this? I’m looking for a light weighted saw for the pallets or ply wood. I hear Black and Decker Circular Saw would be affordable and a good choice but wanted other opinions.

  10. Im so happy i found your pin , i think im going to try doing this myself , even tho im sure my husband will take over lol but you have made this look so much easier then i could imagine, thank you so much and it is an amazing barn door

    1. Thanks so much for stopping by to check out our pallet barn door Karen! Good luck with making one of your own. My husband usually takes over my diy project ideas too but thank goodness he does because they usually turn out way better than they would if I did them on my own :).

    1. Thanks so much for stopping by to check out Pallet door Amanda! The wall color of the room that our barn door is in is Sherwin Williams Kestral White.

  11. love this idea. I love barn doors and want one for my laundry room. thanks again for the detailed tutorial.

  12. Do you think you could stain the wood to make it darker? I love this but I think I’d want to go darker and haven’t used pallet wood before.

    1. Thanks so much for stopping by to see our Pallet sliding barn door Alexis! Yes, I absolutely think you could stain the wood darker. You could stain a small piece of pallet wood first just to make sure you like the look before committing to the whole project.

  13. Came here looking for a simple way to make a door for my mini horse shelter; never expecting to find both easy and fantastic looking. Last one I built looked, well, like a pallet turned into a door. This looks just as easy to make but 100X better. Thanks for posting this.

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