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Windows & Doors

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How-To

Rolling Barn-Style Doors

Simple joinery supports inexpensive windows to yield jaw-dropping interior doors.

Issue 261 - Aug/Sept 2016

 

Synopsis: These elegant barn-style rolling doors take advantage of inexpensive lumber and widely available window sashes to create an ideal weekend project.

On a recent job where I was building and installing new kitchen cabinets, 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 (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. Finished off with a custom shade of green paint and hung on industrial-inspired barn-door hardware (rusticahardware.com), the finished product creates a visual pop against the other wood tones and surfaces of the kitchen.

Locating The Window

After cutting all the pieces and temporarily clamping the door together, lay the window atop the door, and trace its position. Make the cutout 3⁄4 in. inside of these traced lines, then rabbet the edges to receive the sash.

Locating The Window

Spacing The Planks

Cut dadoes 1⁄4 in. wide and about 3⁄8 in. deep into the sides of each plank. Fill them with 7⁄8-in.-wide dry-fit splines to space the planks apart about 1⁄8 in.

Spacing The Planks

Guiding The Door

To keep the hanging door from swinging, apply the planks over the rabbeted frame to create a groove for the floor-mounted stabilizer.

Guiding The Door

Rolling Barn-Style Doors diagram

For more photos, drawings, and details, click the View PDF button below:

 

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Previous: Installing Bifold Doors Next: How to Install a Sliding Barn Door

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Windows & Doors

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Choosing Windows
  • Window Types
  • Design and Materials
  • Energy-Efficient Windows
Installing Windows In New Walls
  • Installation, Start to Finish
  • Head Flashing for Windows
  • Video Series: Nail-Fin Window over Zip System Sheathing
  • Video Series: Nail-Fin Window over Exterior Rigid-Foam Insulation
  • Video Series: Nail-Fin Window over Housewrap
  • Video Series: Nail-Fin Window over Peel-and-Stick Housewrap
  • Video Series: Nail-Fin Window over a Fluid-Applied WRB
  • Video Series: Weatherproof Window Installation
Retrofitting Windows
  • Removing the Old, Installing the New
  • Video Series: How to Replace a Window
  • Video Series: Install a Full-Frame Replacement Window in a Brick Wall
  • Video Series: Install an Insert Replacement Window in a Brick Wall
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Window Repairs
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Door Basics
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Interior Doors
  • Prehung Doors
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  • Custom-Built Doors
Exterior Doors
  • Door Choices and Design
  • Installing Entry Doors
  • Building Exterior Doors
  • Installing French Doors
  • Replacing a Door
  • Adding Weatherstripping and Sweeps

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