A DIY pallet sliding barn door adds a lot of character, saves space, looks amazing, and is cheap and easy to make. Our DIY Pallet Sliding Barn is holding strong & looks fantastic after 5 years now. Learn how to build it and build one for your home today!
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DIY – How to Build a 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 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 diy pallet sliding barn door.
I think our pallet wood barn door turned out great! It brings some rustic to the room, frees up space, and looks really cool!!
Plus, the pallet wood was entirely FREE, making it the perfect diy door project for our budget!
Supplies Needed to Create a DIY Pallet Sliding Barn Door
- Flat Crowbar
- Wood Glue
- Finish nails and nailer or hammer
- 2 wood pallets
- Sliding barn door hardware kit
Sliding Barn Door Hardware
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.
5 Years later & the hardware is really holding up with no issues! Despite having 3 boys opening & closing it 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,
Taking Apart the 2 Pallets to Create the 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 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.
Making the DIY Pallet Sliding Barn Door
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 gluing them and fastening with my finish nailer.
Here’s the bottom half of our pallet wood door 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 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.
I wouldn’t worry too much about adjustments like this.
After all it’s a DIY pallet sliding barn door…it’s not supposed to be perfect!
Hanging the DIY Pallet Sliding Barn Door Up
I cut and 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 pallet wood barn door of your own & answers all your questions of how to build a DIY 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!
If you really like Pallet Projects you might want to check them all out HERE.
Some other DIY door projects you might enjoy