Michelle took a chance and I finally got to do some doors with windows. Love how they turned out!
My picture missed the diamond perforated shelf bases.
Heres a few new ones. We’re now doing authentic reclaimed Barnwood walls!
(My apologies to my customers that came before this. It’s just like iPhone # whatever – you got the best version available by the company at the time.) anyway…
Most barn door builders use a 1×4/6 board 2-3 layer sandwich setup joined with 1.25-2″ 18g bradnails and wood glue. It’s the easy way to do things, and yes, it’s what I used to do up until the last 6 weeks. Now If you use kiln dried pine from a place like Wood Workers Source, it doesn’t matter that it’s pine, it’s kiln dried and will hold its shape over time.
High quality s4s construction pine 1×4/6 boards look decent for door making, and its cheap for the builder. However, I spent a year doing that for the guy who got me into doors and I learned my lessons. You have to pick perfect boards and structurally overbuild It to get it to keep its shape over time. It can be done, but by and large most of the builds I’ve seen done by other people, it’s clear they haven’t implemented the safeguards that allow you to get away with pine. The time you save with hardwood is worth the price you pay. pine has its limits, and it’s not a very sexy wood either.
Enter high end, kiln dried hardwoods. They don’t cost a huge amount more – most door prices will only increase 200-300$. They have more character in their appearance, they’re more predictable in terms of working with and aging, but the thing I appreciate most is the single board edges.
Once you’ve seen a thick one board per side frame, No matter how much you sand the edges of a triple stacked 1×6 door, it will always look cheap and inferior.
Switching to hardwoods has also cut 1/3 the weight off the doors. 50 pounds is huge when it’s hanging on the wall.