Rolling Barn-Style Doors
Simple joinery supports inexpensive windows to yield jaw-dropping interior doors.
These elegant barn-style rolling doors take advantage of inexpensive lumber and widely available window sashes to create an ideal weekend project.
<p>By GreG Soper</p>
<p>On a recent job where I was build-ing and installing new kitchen cabi-nets, the homeowners asked if I also could design and build doors for their walk-in pantry. They wanted to incorporate a barn-style window into each door, but the rest was left up to me. I decided to use divided-lite pine cellar-window sashes ($50, brosco.com) set into shopmade poplar door frames. The frames would be skinned with poplar boards designed to look like a clean version of traditional tongue-and-groove planks. Fin-ished off with a custom shade of green paint and hung on industrial-inspired barn-door hardware (rusticahardware.com), the finished product cre-ates a visual pop against the other wood tones and surfaces of the kitchen.</p>
<p>Locating the window</p>
<p>After cutting all the pieces and temporarily clamping the door together, lay the window atop the door, and trace its position. Make the cutout 3⁄4in. inside of these traced lines, then rabbet the edges to receive the sash.</p>
<p>Spacing the planks</p>
<p>Cut dadoes 1⁄4in. wide and about 3⁄8in. deep into the sides of each plank. Fill them with 7⁄8-in.-wide dry-fit splines to space the planks apart about 1⁄8in.</p>
<p>Guiding the door</p>
<p>To keep the hanging door from swinging, apply the planks over the rabbeted frame to create a groove for the floor-mounted stabilizer.</p>