Barn Door

 

In our house, we have a walkway that was just asking for a Barn Door. So I had no choice, but to build one.

Except they don't make the hardware for a walkway like the one we have in our house. But I had some plywood leftover from the gym project (protecting the walls from handstands) and know a guy who can weld, so the project was a go.

So I ordered the hardware ($50, track is included).

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Cut up the 1/2 inch plywood sheet into two 6 inch strips & nine 4 inch strips. The reasons for both 6 and 4 - I wanted to make the 2nd layer out of 8 inch strips, and wanted to make sure the cut lines were visible when overlayed. Also when running the saw I made the cuts a bit off on purpose, to make the door look more "rustic" when finished via slightly uneven and not very tight gaps.

Starting on the 2nd layer. It's there to both give it the design and stability. The outer layer was made of 3/4 inch plywood. The original layer is half inch. 

All put together. with the interior 1/2 inch pieces inlaid. It's the same plank in the middle that the main layer was made out of.

Mocking it up. The track was welded in the middle (it's normally two pieces that snap together). A flat plate was welded on the end with 4 holes drilled out. That was the most elegant solution I could think of when working around the problem. I found a somewhat matching dark bronze paint to spray over the weld - looks clean enough. I had to file down the little trip piece on the edge (you can see it to the right of the left sliding hardware piece) - the bolt behind the sliding wheel was hitting it. Touched it up with paint as well.

I noticed the floor sloped in that part of the house (it's relatively old), so the door jammed on the floor about a foot before closing, so I took it down and cut it a tad. That's not quite true - the entire door had to be taken apart to cut down both the main layer, the center inlays and also the 8 inch side pieces.
All the screw holes were filled in as well as the gaps at the bottom.In retrospect, I should've just screwed everything from the back, but I was just starting out on my projects.
Everything was sanded down & ready for paint.

Let it dry, then put the sliding hardware on. There's some hardware that goes on the track, that I originally forgot, so the track had to come off partially & the stopped slid on into place.

Put the handle on the front, plus a smaller one on the front and a small hook latch on the back, so that the door can be closed from behind.

Total cost to me was only 60 bucks. Fifty for the sliding hardware & track, plus 10 or so for the handles/latch. Plywood and paint I had leftover and a great friend with welding business.

Overall the door looks great. It's been over a year and it's fantastic. Fairly easy and cool piece to do. 

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P.S. I totally forgot to put a notch on the bottom of the door for the sliding guide (so that the door doesn't swing back and forth and only moves left and right). Because of the sloping floor it ended up being a non-issue anyway, but if you're building one - make sure you do that early on (aka read the instructions, which I didn't pay much attention as usual).