Introduction

Building a wooden door that is strong, sturdy, and resistant to warping can be a challenging task. However, in this article, we will explore a step-by-step guide on how to create a barn door with floating panels. By following these instructions, you can ensure that your wooden door will never warp, and you’ll be able to impress your clients with your woodworking skills. Let’s dive in!

Key Points:

  1. The Ninja Woodworker’s tight deadline challenge:

    • The Ninja Woodworker decides to take on a client’s project with a tight deadline of only six days.
    • Despite the challenge, the woodworker is confident in their ability to complete the project successfully.

  2. Gathering the necessary supplies:

    • Before starting the project, it is essential to gather all the required materials. This includes wood, handles, and sliding door hardware.
    • The woodworker visits a hardware store to purchase the necessary supplies.
    • Due to limited stock availability, the woodworker decides to work with one-inch thick cedar stock instead of the desired two-inch thick stock.

  3. Creating the floating panel design:

    • The woodworker cuts 24 pieces of the cedar stock to two feet long.
    • To create floating panels, the woodworker adds tongue and groove to each side of the cut pieces.
    • The floating panel design allows for seasonal wood movement without warping.

  4. Building the door frame:

    • After the lumber arrives, the woodworker begins laying out the styles and rails to conceptualize the door’s construction.
    • A change order from the client requests a chevron panel design instead of the original floating panels.
    • The woodworker uses a joiner and planer to mill the lumber and created the desired chevron panel design.
    • Styles and rails are labeled, tongues and grooves are cut, and a dry fit test is performed to ensure a perfect fit.

  5. Overcoming challenges and setbacks:

    • Despite feeling overwhelmed by the project, the woodworker remains committed to completing it successfully.
    • The woodworker manages to modify the floating panels’ size to accommodate the chevron pattern.
    • Cracks and checks in the wood are stabilized using ca glue and tinted to match the desired stain color.
    • DIY plans and a cut list are provided for reference.

  6. Hardware installation and finishing touches:

    • The sliding door hardware arrives slightly late, but the woodworker continues forward.
    • Holes for the hardware are drilled using a jig for accuracy.
    • The woodworker applies two coats of finish to the door, ensuring it cures fully.
    • The door is hung, completing the project just in time for the deadline.

  7. Client satisfaction and additional projects:

    • The woodworker advises the client not to touch the freshly finished door for the night.
    • The overall result is a beautiful and functional barn door that impresses the client.
    • The woodworker showcases additional projects like a live edge bath caddy and a reclaimed mantle.

By following this comprehensive guide, you can confidently build barn doors that will never warp. The careful attention to detail, use of floating panels, and overcoming challenges will ensure your creations stand the test of time. Display your woodworking skills with pride knowing that you have mastered the art of constructing warp-resistant doors.