Replacing/Fixing barn doors

[l8_apexer]

I have 4 barns on our property. 6 of the doors need to be replaced--- due to wood rot, boards falling apart, insect damage. Have scoured the internet and have little to no information on how to replace the doors.

Appears that the only solution is to make new doors myself-- again- little information has turned up in the search.

The doors are sliding, hung from the top and have a track they "slide" (ha!) in. Does anyone have suggestions on where to find information on making new doors? I can't find a place to buy sheets of metal siding to use to make the doors. I've found a few places that sell the hardware-- will I have to plan on replacing the tracks at the same time?


Thanks. Any suggestions welcomed

 

[rtimgray]

The way I go about making barn doors is relatively simple (or else I couldn't do it!).

I measure the opening that I want to cover, and decide if I'm gonna use one or two doors. I usually use big swinging doors, but we've not a few sliding as well. The door construction is essentially the same, but the sliding doors will be a few inches wide for a given opening because you probably want an overlap on the side.

Example: The opening for the barn is 10' wide x 10' tall. For swinging doors, I would make a set of doors frames 4'-10" wide x 9'-10" tall (you will have a space in the middle, but you can cover it with an overlap of metal).

Anyway, decide how big you want the door. I usually use 2 x 4s for the frame (although for a really big sliding door, we have used 2 x 6s. Then I cut the outside frame members with 45 degree cuts on each end (basically, make a mitered frame). Lay them all down on a flat surface and put a screw through the ends. Take a few minutes, measure the diagonals, and square the frame. Then I cut a board to bisect the big rectangle, and make to small ones (put it equal distance from each inside end). Toe-screw it to the outside frame.

After all that, I cut diagonal braces to run from what will be the inside bottom and inside top corners of the door to the middle of the middle (that really doesn't seem to make sense, does it). Anyway, you will probably have to cut and recut and test fit some times.

After all that, you should have a frame laying down that looks like a digital "8" or possibly upper case "B" with half an "x". (Maybe I should just make a drawing and post it). After checking for square again, I put metal mending plates on each junction of wood. I use the kind that have a bunch of holes and just put 1" drywall screws through the, at least 3 per board. This will be the inside of the door.

After that, you have built a braced frame. You can now stand it up in the opening. I usually use cut off chunks of wood and brace it up how I want it and then attach the hinges. If it is a hanging door, you will need to attach the roller hangers to the top of the door (usually have to drill through the top member) and then slide it in the track.

Finally, after all that, I hang the metal on the door. On sets of swinging doors, I start in the middle and make sure that the ribs of the metal covering from each door will overlap in the middle, and cut the rest of the metal to fit.

Wow - that looks really convoluted. It's really not that difficult. If I get a chance, I'll post a sketch of what I'm talking about it should be a lot clearer.

Good luck. Take care.

 

[weldingisfun]

l8_apexer, like rtimgray said, it isn't all that difficult. It would help if you would provide a couple of pictures showing what you are up against. Include a few detail pictures showing the hangers and other hardware.

 

[Runner]

Here's a pic of some swinging doors I made. They are very lightweight, and I was concerned that I might not have enough diagonal bracing (wound up using the plywood corner braces) but so far they are holding up fine.

I had a hard time finding a distributor of metal barn siding in my area too, but the salesman at the local Tractor Supply steered me in the right direction.

 

[zzvyb6]

My barn doors are 2 sheets of 4x8 sheets of plywood. Outside sheet is T1-11 wide groove. They are horse kick proof.

My shed doors are made up of single sheets of 4x12 T1-11 with an inner 2x4 framework. Easy to make, replace and maintain. Keep them 1/2 inch off the ground and use a weather strip to keep out the snow.

 

[excelagator]

I have co worked that built sliding doors for a shop. They are interior doors. He used livestock door hardware. The doors were framed, drywall and insulated, real heavy. They were quite nice though! If your looking for the hardware may want to try a metal building contractor.

 

[rtimgray]

What Runner posted is pretty much how I make them with the exception of the diagonal bracing. I bet that the plywood gussets that he put on them make up for the braces - so the door is just as strong, but probably lighter and cheaper (I like light doors). Thanks for posting the picture.

Take care.

 

[Runner]

Yes, the plywood helps stiffen them up a lot. The metal siding helps a lot too, once all the screws are in place.

 

[RobJ]

Can't you just copy the ones you are replacing?

 

[yzbdsbp]

I too am wanting to enclose my barn, and thanks for posting some pictures, the more pics the more confident I feel that I can tackle making the doors for this project. The thing I am having trouble with is finding the right king of hinges, could yall post some pics of the hinges you guys used or describe them in detail......... Thank you so much

 

[thl]

I have a ten foot wide by eight foot tall sliding door on a pole building. It slides shut against a perpendicular surface. I'd like to lock it from the outside however I'm having some difficulty finding door hardware. I'd like something more elaborate than just a hinged hasp and a padlock. Any ideas on door hardware out there?

Thanks,

Terry

 

[l8_apexer]

thanks for all the help and suggestions. Gueess that building doors won't be as challenging as I feared. The orginal doors and made with tongue-in-groove siding. Don't think the budget can support replaced with the same style and materials. Was thinking about making a frame (thanks for the how-to's) and then used steel siding-- the problem is bee I can't a place that sells the steel siding. Was at the farm the past 3 days-- had a neighbor stop by and told me of a source for the steel siding in a town about 40 minutes away.

From the posts, seems like there's a lot of old doors that need fixed or replaced!

THank you all so much!

 

[riptides]

From the posts, seems like there's a lot of old doors that need fixed or replaced!

I have an old dairy barn that I have been fixing up for the last four years. I just replaced the doors a few months back. I used regular plywood and framed it out with 1X6's on the horizontal edge and verticals. I also replace the runner, and all door hangers. I'll post pics tonight.

The doors about 3/4 the weight of the original tounge and groove they replaced. It was about a day job, you just need a flat suface to make everything straight and true.

 

[Farmer Brown]

Did you ever post the pictures of the barn doors? Thank You

 

[warhammer]

The bearings and hangers can likely be sourced at a Mueller Metal building depot if you have one near you.

I have 4 barns on our property. 6 of the doors need to be replaced--- due to wood rot, boards falling apart, insect damage. Have scoured the internet and have little to no information on how to replace the doors.

Appears that the only solution is to make new doors myself-- again- little information has turned up in the search.

The doors are sliding, hung from the top and have a track they "slide" (ha!) in. Does anyone have suggestions on where to find information on making new doors? I can't find a place to buy sheets of metal siding to use to make the doors. I've found a few places that sell the hardware-- will I have to plan on replacing the tracks at the same time?


Thanks. Any suggestions welcomed