A DIY pallet sliding barn door adds a lot of character, saves space, looks amazing, is cheap & easy to make.
Our DIY Pallet Sliding Barn is holding strong & looks fantastic after 5 years now. Learn how to build a pallet sliding barn door for your home today!
Table of Contents
DIY – How to Build a DIY Pallet Sliding Barn Door
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Since Tucker’s room was originally a master closet it was long & 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 & get the door out of the way we decided to give him a DIY pallet sliding barn door.
I had some pallets in the garage leftover so I decided to try and create a DIY pallet sliding barn door.
I think our pallet wood barn door turned out great!
Who wouldn’t love a barn door made of pallets?!!!
His DIY pallet sliding barn door brings some rustic character to the room, frees up space, & looks really cool!!
Plus, the pallet wood was entirely FREE, making it the perfect diy pallet door project for our budget!
Supplies & Tools Needed to Create a DIY Pallet Sliding Barn Door
- Flat Crowbar
- Circular Saw
- Wood Glue
- Finish nails and Nailer or hammer
- 2 wood pallets
- Sliding barn door hardware kit (similar to this ONE for a DIY pallet sliding barn door)
Sliding Barn Door Hardware used for our DIY Pallet Sliding Barn Door
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 less money including shipping.
5 Years later & the hardware is really holding up with no issues!
Despite having 3 boys opening & closing our DIY pallet sliding barn door constantly.
The hardware is really high quality and I would definitely recommend it if you are in the market:
You can find A LOT of different sliding barn door hardware on Amazon,
Step by Step Instructions for How to Make a Barn Door Out of Pallets
Size of our DIY Pallet Sliding Barn Door
Our pallet sliding barn door is 80″ tall by 33″ wide by 1.5″ deep but you can make your pallet door any size you want!
Step ONE – Taking Apart the 2 Pallets to Create the DIY Pallet Sliding Barn Door
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.
To read more how we take apart a pallet before making your DIY pallet sliding barn door (check out this post here)
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 pallet sliding barn 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.
Step TWO – Making the DIY Pallet Sliding Barn Door Top, Bottom & Center Rails
I started by making a top, bottom, and center rails for the pallet sliding barn 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.
Step THREE – Attaching the Vertical Pallet Boards to the Horizontal Rails to Create the Pallet Sliding Barn Door
Once this was done it was a simple matter of sliding the vertical boards into the horizontal rails while gluing them and fastening with my finish nailer.
Here’s the bottom half of our pallet wood door done.
Step FOUR – Sanding Down Your Pallet Sliding Barn Door
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.
Step FIVE – Attaching your Sliding Door Hardware & Completing the Pallet Door
Once I got the hardware installed above the door I realized the pallet wood barn 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.
Don’t worry about adjustments like this… a DIY pallet sliding barn door…it’s not supposed to be perfect!
Step SIX – Hanging the DIY Pallet Sliding Barn Door Up
I cut & added a few more pieces of pallet wood to the pallet sliding barn door for the roller bars to fasten to.
We couldn’t be happier with how our DIY Sliding Pallet Barn door turned out!
It is the perfect pallet sliding barn door to separate our boys rooms.
And… it looks Fabulous!
I hope this inspires you to create a DIY pallet wood barn door of your own & answers all your questions of how to build a DIY pallet sliding barn door!
by Tara Lehman
To see more of Tucker’s room (which used to be a closet), including his bead board ceiling, bunk beds, closet doors, how we built his bookcase & window seat, added a window & wide pine floors, you can check that out here.
Don’t forget to Save & Pin our Pallet Sliding Barn Door or follow along at Pinterest!
If you really like Pallet Projects you might want to check them all out HERE.
10 Pallet Furniture Projects to Try
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.
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
What a great job! It looks amazing!!
How creative! glad to hear about the barn hardware from Amazon….if I ever get the opportunity….
Thanks so much for your sweet comments about our pallet barn door Nancy! Take care, Tara
Love the door pallet, amazing job, The wood looks very old.
Thanks so much Maria!!!
Love your take on the barn door, and I would imagine it is not as heavy as using typical wood slats. Very nice! I’m visiting from Amaze Me Monday.
Rita C at Panoply
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
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 ..)
Sorry – initiative
Thank you so much for stopping by and your kind comments! The hardware allows the door to slide very smoothly:). Take care, Tara
We saw a sliding barn door at a furniture store this weekend, and my husband instantly fell in love with the idea of replacing a hard-to-close pocket door with one. Love how the pallet wood gives it an instant antique feel. This would be perfect!
Thank you so much for your kind comments Vineta! In my opinion barn doors are definitely easier to slide than pocket doors:). Take care, Tara
I”m totally crushing on this door! I’m a huge fan of reclaimed wood so this is right up my alley. Thanks so much for stopping by The Creative Circle link party 🙂
Thanks so much for stopping by and for your sweet comments LZ!
I am so glad I found your site. I have been looking for a tutorial like this. Awesome job! This is getting pinned.
Thank you so much for stopping by to check out my pallet barn door!
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!
Sharon, thank you so much for the feature,the party and for stopping by! It was incredibly sweet of you! Take care, Tara
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!!
Thank you so much for stopping by and for your sweet comments about our pallet door Melissa!
I love this!! I have a pallet sitting in the garage but where do I need a sliding door? Great job!!
Ha! Thanks so much Susan!!
This is gorgeous and just think…you are saving the world. Love this idea. totally pinning!
Ha, thanks Jess!
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
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!
This is beyond awesome!!
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.
Hi Samantha! We have had the barn door up for almost 2 years now and the hardware and the door are still in fantastic shape.
Do you have any problems with the bottom of the door banging, or the door swinging out from the wall?
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!
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
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.
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.
Thanks so much for stopping by to check out our pallet door Tammy! We used our Dewalt circular saw to cut apart the pallets.
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
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 :).
I love the barn door!!! What color paint did you use behind the barn door?
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.
Is Kestral white what you used throughout main areas of your house? It looks creamy. I love the blue in your sons room, will you share the color? We have Plaster also!! Remodeling our small bedrooms adding shiplap to ceiling vs. beadboard, why did you decide on beadboard? Thanks!!
Thanks so much for stopping by to check out our farmhouse Jane! Yes, Kestral White is what we have used in our living & family rooms, hallways & my son’s bedroom. It is a cool cream neutral white in my opinion. The dark blue we used in 2 of our boys rooms in Benjamin Moore’s Hale Navy. We chose Bead board on the ceiling on our son’s bedroom because it weighs less than shiplap. When we remodeled his bedroom, shiplap was harder to find in stock at our local hardware stores. We do love shiplap on our walls & have been slowly adding it to different rooms around our home & most recently to our foyer. Good luck with your bedroom remodel, plaster walls & ceilings are no fun!!!
love this idea. I love barn doors and want one for my laundry room. thanks again for the detailed tutorial.
Thank you Susie!
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.
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.
I love this door, and need about eight, but the hardware is much to expensive. Happy New Year!
Ha, yes we really love our pallet door Ivory!
Love this!! Let you know how it turns out.
Thanks for stopping by Kym! I would love to hear how your Pallet Sliding Door turns out, good luck!
Is the door wobbly in the center where the boards meet?
Thanks so much for stopping by to see my pallet sliding door Clarisa! No the door is not wobbly in the center.
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.
thanks so much for checking out our pallet sliding barn door! Good luck making one for your mini horse shelter!!!
Magnifica puerta corredisa, sencilla , practica y economica. Tratare de hacer algo parecido.
Gracias, Nelson! And good luck with your sliding pallet door!
I love barn doors and want one for my laundry room. thanks again for the detailed tutorial.
Thanks so much for stopping by to check out my pallet sliding barn door John! Good luck making one in your laundry room.
What method did your husband use to “make the notches” in the top, bottom, and center rails? I hope to mimic this door for our own door in the entryway from formal dining room into the kitchen.
Thanks for stopping by to check out our DIY Pallet Sliding Barn Door Dave! He made the notches for the top, bottom & center rails with his tables saw setting the depth of the table saw blade to the size you want your notch to be. Good luck creating a pallet door for your dining room!