Today I’m going to Share with you a $50 DIY British brace barn door. If you’ve been following me on my Instagram (remingtonavenue) then you know we have been slowly plugging away at finishing our basement… now I can check this one off the
list! We added a theater room down there with a large opening. A DIY barn door seemed like the obvious choice! I did a ton of research before taking on this project. I found some great barn doors on pinterest but all of them seemed a lot more involved than I wanted to get. So I put my DIY loving thinking cap on and came up with simple and affordable solution. Read on as I show you exactly how I built this budget friendly $50 DIY British brace barn door and what materials I used!
To begin building the British brace barn door I started with a 4×8 sheet of pine plywood that I purchased at Home Depot for 34.98. That was the majority of the cost.
The opening to my theater room measures 42 inches (3.5ft)wide by 81 inches (6.9ft)tall. I had the nice man at Home Depot chop a foot off the length to bring the size down to 7 ft. This allowed for 3 inches overlapping on the top of the door way and 3 inches overlapping on each side. Measure TWICE, cut ONCE! Can anyone else hear their dad yelling that in the head?! Seriously though, make sure to take accurate measurements and allow for overlapping on both sides of the door!
Since the plywood is the base of the Barn door, give it a good sanding. I sanded mine with my orbital sander on both sides. If you don’t have an orbital sander, no sweat, just use a hand sander to smooth out the rough spots. I added 1×4’s around the edges of the door and to create the British Brace pattern (sideways V). I used a 1×6 for the middle of the door. These are all common boards that come in various lengths. Make sure to check for warping when your choosing your boards cause that can really mess things up. Select the straitest boards you can find.
I had the same nice guy at Home Depot cut the boards to my specified measurements. If you are building this exact door, the top and bottom 1×4’s can be cut to 40″ or 3.4ft. The other 2- 1×4’s can be cut to match the length of the door 7ft.. These 2 boards will run along to sides. The 1×6 board should be cut to 40″(3.4ft) and will lay across the center of the door. I saved the other 2 boards (1×4’s) that create the British brace to cut at my house once the other boards were in place. I drew up a quick plan below to illustrate the sizes. (My plan illustrates 1×4’s on top and bottom, but they are actually 1×6’s sorry)
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Once my plywood sheet was sanded, I applied gorilla glue to the back of a 1×4 and placed it at the top of the plywood. Make sure to align all the edges.
I nailed the outside trim sides (1×4’s) to the sheet of plywood using 18 gauge, 1-1/4 inch finish nails and my Bostitch nail gun. I repeated this on the top and bottom 1×6’s to complete the outer frame.
I repeated this process on the sides and bottom to create the outer frame.
I glued and nailed the 1×6 to the middle of the barn door.
For the British Brace at the bottom of the door, I cut and measured a board the length of one corner to the other by lining up the middle of the 1×4’s in the corners.
Then I just marked with a pencil where I needed to make the cuts.
I applied gorilla glue to the back of the bottom British brace and then nailed it to the door.
I repeated the same measuring tactic as above and glued and nailed the top of the British Brace in place.
Once the Barn door was complete I filled in all the nail holes and imperfections with Elmer’s Wood Filler. This wood filler changes color from purple to neutral when its dry and ready to be sanded! Fancy!
I sanded all the edges of the barn door thoroughly. You can even see I had a little overhang on one of the outer frame boards. I sanded it down so it was even with the plywood.
And just like that I built my first ever barn door with a British Brace!
Get The Supplies
Now that my barn door was built, all I had left to do was paint it. I sprayed it with 1 coat of primer on both front and back of the door.
I also caulked any cracks between the plywood and trim to get rid of any gaps. Remember Caulk is a girls best friend!
Once dry, I sanded the door one more time using a fine grit sandpaper.
Then I sprayed the Barn door with 2 coats of Whisper White Enamel paint by Behr. Same color as all the trim throughout my house. If you don’t have a sprayer don’t fret, A brush will do the trick just fine!
I installed the Barn door with this rolling door kit from The Barn Door Hardware Store. I selected the 8ft track (double the size of my door). I was thrilled when it showed up. The Barn Door Hardware Store provides a high quality product and comes in unfinished raw steel. How awesome is that! You can choose whatever finish you want by spraying it with Rustoleum High Performance Enamel Paint. I selected the Matte Black.
I love my barn door hardware so much that The Barn Door Hardware Store has agreed to offer 10% off any hardware to all my readers! Just pop on over to their site and enter the promo code: Remingtonavenue when you check out.
EACH SLIDING BARN DOOR HARDWARE KIT INCLUDES:
Two hangers/straps (1.5″ WIDE) with 3″ x 1.5″ cast iron wheels for years of wear – rated for 300 lbs weight limit
1.5″ steel track with positionable end stops – track available in almost any length
All hardware needed to attach hangers to your door and track to the wall
Two anti-jump stops to prevent sliding barn doors from accidently coming off the track – for your safety
One easy-to-install, floor-mounted U-shaped door guide for doors that are 1 3/8″ to 1 3/4″ wide
The finishing touch to the barn door was the unexpected crystal door knob .
Pow! DIY British brace barn door for $50 and nobody would ever guess it was built for that cheep!
I love this DIY barn door so much! Not only will it block all the light for our soon to be theater room, but it looks pretty rocking too.
I hope you loved my budget friendly “DIY British brace barn door for $50!”
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