How to Make Barn Doors // Woodworking & Metalworking | I Like To Make Stuff

The barn on our new farm needed some new doors, so we made some out of steel and cedar. Want to see how we made these actual barn doors, come check it out!
WE BOUGHT A FARM! : • We Bought a Farm! [Far...
JIMMY DIRESTA'S BARN DOORS: • DiResta BIG Barn Doors
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If you don't know, we recently bought a farm, and on the farm there is a barn (sounds like a kid's song). The barn has one large sliding door for the main building, but there is a side room that is supposed to have doors as well. The previous owner took the doors out and replaced them with a cheap wall. Well, that wall is rotted and gross and I want to be able to open up that space. Time to make some barn doors!
I cut the nails holding in the patch wall and smashed the rotting structure out. This exposed the previous door jams and the area i needed to measure for the new doors. Armed with these measurements, it was time to cut some steel for the new frames!
Now that I had the measurements I needed to begin the door construction, I started cutting the 90-degree steel beams. I used the metal-cutting bandsaw set to 45-degree angles to cut all eight pieces that will make up both door frames. Using the MIG welder, I welded the pieces together making two huge rectangular frames. To prevent the door from sagging over time I welded a piece of flat stock from corner to corner across each door. I used the angle grinder to clean up the welds and added a coat of black enamel paint to each frame.
As noted by my line of outdoor projects, I love the look of cedar and black metal. Cedar is also great to use in outdoor applications, so it was a natural choice. I used cedar pickets instead of regular dimensional lumber, because the wooden panels were not as structurally integral. The cedar panel will sit inside the 90-degree steel frame and will be held in place using stainless steel screws to prevent rusting. I cut the cedar pickets at a 45-degree angles and stretched it from corner to corner. To make sure that both doors' boards matched up, I cut the boards in pairs and laid them down in a herringbone pattern. To finish off each panel, I screwed down a cedar frame around the edges to tie the boards together and to connect them to the steel frames.
Now that the doors were done, I welded on some large hinges and took them out to the farm. To ensure a consistent spacing on the bottom, I set down a piece of scrap 1/8" wood. Josh helped me move the doors in place while I screwed the door hinges to the door frame. The second door went in the exact same way. We added a 4x4 to the inside of the barn, above the doors to act as a header and to cover the gap above the doors.
I bought some aluminum gutter material to act as exterior door trim. We cut it the the bandsaw and trimmed out specialty cuts with my Maker Knife. All the barn doors needed was a door latch. I placed the sturdy door latch on the inside of the door to keep a clean look on the outside. I don't plan on using that space as a primary entryway, so it was ok that the lock was on the inside.
I really like how this project turned out. It makes a huge difference when you're driving up to the barn and now that side room is accessible from the outside! I have some awesome plans for that space and the barn as a whole. I hope you like this new venture, and stay tuned for more projects out there!
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How to Make Barn Doors // Woodworking & Metalworking | I Like To Make Stuff
• How to Make Barn Doors...
I Like To Make Stuff
/ iliketomakestuff

[@JoshMakesStuff]

Yes, there is a locking mechanism on the inside of the door. First!

[@Wordsnwood]

Kudos on the brilliant intro. Great job, guys!

[@skeezo]

How's the sunburn on your legs 😂

[@Volvary]

If the hinges are a risk, you guys may want to look into Jam Pins. (TL;DR, Jam Pins are replacement screws for hinges that have protrusions sticking in the opposite hole in the hinge. As long as the hinge is closed, those pins acts like mini-deadbolts, even if the hinge is unscrewed from the outside.)

[@saulbrysen5125]

i know it's kinda off topic but do anybody know of a good website to watch newly released movies online ?

[@abdullahgideon9391]

@Saul Brysen Lately I have been using FlixZone. Just google for it :)

[@OutoftheWoodwork]

"I just want to give you a little encouragement". I think that's what makes this channel so great, Bob - you've never been about showing off or negativity. Thanks for making a show I never think twice about letting my kids watch!

[@Iliketomakestuff]

Thank you!!

[@FigmentsMade]

These doors really do dress up the barn. They look great! Chucking the hex screw into the drill is an excellent tip! And using gutters for the trim is brilliant! That intro though... 👍👍

[@JoshMakesStuff]

Figments Made I have my moments

[@com38ful]

Bob Clagett, kicking ass and painting grass since 2013

[@forby_]

Hahaha

[@DanteNava]

I haven't seen his painting grass video, but that IS a thing!!!

[@mr.robinson1982]

I have used a magnet inside a Ziploc bag to pick up all the metal filings from my work bench & floor. I have to have a debris free floor as I have a dog. Also, you always put the brace from the bottom-->top(that is near the hinge) to keep it from sagging.

[@zeitlinger5844]

That Intro is one of my favorites!

[@DennerBob]

Super simple in-camera trick, and it's one of the coolest visuals I've seen in a while!

[@hand_emoji8280]

Hyrule me too

[@IMEEMADE]

That intro though! My favorite part of the day so far

[@scottblankenship9644]

Hey Bob , on the angle cut where the flat side was on top , just use a piece of box tubing to vise it in with .Do it all the time at work .

[@Green-hg5hc]

Top aluminum trim will gather water during rain Hinges can be unscrewed from outside, so its better to place them between door and stand.

[@Devin292]

Even though it's been filmed. I still find myself closing my eyes during the welding. Great project

[@fedor5664]

Lol me too XD

[@davidboyce6975]

As do I ...

[@ThisDoesNotCompute]

That welding montage was really nicely put together!

[@Iliketomakestuff]

Thank you!!

[@jonchio8011]

What happened with the ants? You can’t just leave us with a cliffhanger like that bob!

[@YouCanMakeThisToo]

This might've had my favorite intro you've ever done. Also really like the gutter idea for the flashing! Good reminder to not get stuck looking for "exactly" what you need, but something that can be what you need, or at least solve the problem (not having a metal brake).

[@MakeEverything]

This intro, 10/10!!!!!

[@mischieftim8249]

The little birdie and the bye at 11:40

[@badassfood5713]

Hey, Bob. This was a very enjoyable show. Probably the best I have seen from you in a while. You nailed the format, and the content. Love the mixed media great cinematography. I could easily see this as an afternoon diy show on any number of national networks. Great video.

[@ryans600]

Now that... THAT was a good opening transition 10/10

[@BR0JASON]

Two things: 1) You may want to reconsider the SS fasteners because you're risking galvanic corrosion unless it's protected from the carbon steel. 2) Bob...dude...cover yourself when you're welding. UV rays don't play.

[@mainlinx]

He is safe from the galvanic corrosion. The stainless Steel hardware that he used will almost mitigate any type of corrosion at all. There are several articles that are available that support the use of stainless steel hardware with other materials. It is used because of the noncorrosive properties.

[@KJM321]

Aren't you also not supposed to weld on concrete? Isn't there the risk of the concrete exploding?

[@tonyhandsome]

Galvanic corrosion happens when there is potential differences between the two metals so if there is no electricity near by you should be safe, but its better to paint (or isolate) those holes so the metals don't touch.

[@johnb8579]

Actually, any galvanic corrosion resulting from the contact of two metals will just erode the hole bigger (since it's the "less noble" metal). What WILL happen, however, is what's called "crevice corrosion" that will happen at the point where the screw threads that are exposed to the air meet the portion of the screw that is buried in the wood which will always be somewhat damp.) This is commonly known problem in the marine environment. That's why virtually everything is through-bolted with a nut and washer on the back side. What he should be using is coated deck screws that are designed to resist corrosion inside the wood. In addition to his flashing deficiencies, he also should have put an astragal on one or the other of those door leaves where they meet in the middle.

[@rtrspb]

@@Captn_Grumpy I had same thoughts and deside to check other comments... so, I'm not alone )))

[@UltimateTechHub]

Hi, I'm Mike and I like to watch Bob make Stuff! Nice solid Barn doors but you should put some handles on them that would make it look finished and functional! Thumbs up!

[@dwalmop2]

You've got the steel bracing in the correct direction. It's so long and thin that it can't take any reasonable compression. Perfect to use for a tension brace.

[@dreederiv]

the gutter flashing on the header may collect water ya might wanna seal it or pop some weep holes in it great looking doors

[@andrewpaterson4672]

Bob welding in shorts, like a BOSS.

[@terjebe7317]

A small tip for you all: Use pythagoras to calculate the length of the cross bar. This way you are sure that the angles are square even after welding.

[@MikeTheMaker1]

terje bøe measure corner to corner and give it a good smack to square up if it’s still off.

[@MrMrMeile]

tension is for flat steal correct, compression would require an angel iron or it would bow out

[@johnalexgartner9523]

:-)

[@Hall_Meli]

While I love your videos regardless, I always love the little random elements, like the "Hey" and "Bye" for the moth or bird that was flying into your shot as you put the doors on LOL

[@s.schimke6591]

Small kind of bird?

[@carlosarthurpetry3674]

For a steel brace made out of a flat bar, you've done it in the correct direction.

[@kyleverno]

even if done with cable would be done right

[@carwynowen452]

Yes I agree totally, wooden door braces are designed to be in compression, but with steel doors and gates, the brace wants to be in tension! Interestingly, the wood on these doors will probably act like a compression brace in themselves, I’d be surprised if these doors sag much!

[@byejason]

Agreed. I was taught when it comes to bracing, you hang a metal gate and prop a wooden gate.

[@adamfaris4224]

I am late to the party but came to say the same thing. As engineer flat bar like that should be tension as he did. Being screwed to the wood would help in compression by reducing the buckling length but tension better. Thank you to the reply about hang metal prop wood gate. I’ll remember that

[@christobaben3944]

I think there might be an issue for when it rains and getting water into the top of that frame. It looks as though there is no flashing

[@Dingbat217]

Bob from the future, the brazing under tension is the correct way to do this with steel straps, steel will bend under compression but is very strong under tension. Wooden razes are the opposite, weak under tension but strong under compression which is why they are installed the other way around. :-)

[@negotiableaffections]

Repurposing guttering. A brilliant tip that demonstrates that simple solutions can often be found. It looked to me like the utility knife gave the cleaner cut but scoring those long lengths.... yeah, go bandsaw! Great job, Your doors are cute....Jimmy's are just, show-off!

[@cliffdoes_stuff4012]

I don't currently own a barn but I am sure I got something from this video (stored away for use at a later date). Great to see new projects out at the farm, I'm looking forward to the next video and it's always good seeing Josh in front of the camera.

[@Iliketomakestuff]

Thank you!! i hope there's always a little tip or trick that may be handy someday down the road 👍🏼

[@derekl_]

You should put either offset pickets, counter angled pickets, or 3/4 plywood behind the doors on the inside. I noticed when you were closing them that light from inside the barn came through the picket slats which means wind and rain can too. Putting a backing on the inside of the doors will close those up - and if you do a weather proofing between the pickets and the plywood, the plywood would give you a mounting surface for more stuff that won't poke through the outside pickets.

[@suearmstrong3404]

Love the cedar pickets! I used the pressure treated pickets to make gates, one for humans and one for the lawn tractor to get from the back yard to the front yard. I also used them for siding on a small shed. Easy to use and inexpensive!

[@TheStampede000]

I'm 31 years old and I just learned that you can cut a gutter with utility knife, nice!!

[@travisjicorcoran5870]

That top flashing is...interesting. You created a gutter that will capture rain and hold it against the wood framing.

[@andrewcallard222]

One of my biggest dreams is being in the same room as Bob or Jimmy Diresta and hearing Bob saying Jimmy’s name in a sentence just made my heart melt, these guys are huge inspirations of mine, keep making guys!!!!

[@johnstone4657]

Bob, I love your videos. I am always excited when you post a new one. You have inspired me to step up my hobby game on many levels. Thanks for all of the hard work you and your team do.

[@klogsdon31]

A little bracing info from a structural engineer: The bracing direction all depends on the cross section of the brace being used and the fastener type. The current configuration has the braces in tension, which is perfect because the thin profile of the bar would buckle under compression load. Also, because it’s welded, there’s no slip in the fasteners like you might have if you had screwed a wood brace inside a frame. Wood usually is the opposite direction because it’s a larger section and can hold a higher compressive load without buckling. Also, like I mentioned before, you can’t weld wood together so you will always have slop between the screw, but in the compressive condition, the load is transferred through direct bearing of the brace on the wood frame, not through the screws. Hope this helps make sense of material science and structural design!

[@Iliketomakestuff]

That's awesome information, thank you for sharing!!

[@NelsonJ1]

What if you made an X instead of one cross brace. Would that strengthen the door?

[@kennyken3889]

Very good watch again!!!

[@landmarkcreations1183]

Absolutely incredible job Bob!Your videos never get old. Keep up the great work!

[@AtrumNoxProductions]

The projects keep getting more and more amazing, yet still something that most shops can do. I am also loving all the new cinematography that is evolving as well. I have also noticed your welding get smoother and smoother.

[@r.j.sworkshop7883]

Hey Bob, nice doors. When I am clamping angle in a vise for the chop saw or the band saw, I use a block of scrap wood inside the L of the angle. This way the vise is clamping on the vertical portion of the angle and not relying on the thin horizontal piece to hold all the load. Obviously you didn't have any problems, but if the blade jams or anything it is a little more secure having that solid block inside the angle. Thanks for another great project. R.J.

[@DominusFeles]

Gold star for that intro! 🌟

[@botonramz]

Oh that opening transition #chefkiss

[@b4ux1t3-tech]

The best part of this was the butterfly admiring some great work by Bob and team.

[@dhackl5741]

Christopher Pilcher Hey, bye.

[@davegray02]

Loved the butterfly easter egg in there! Great video as always

[@teckbugz1278]

Awesome! I can't wait to see other barn projects!

[@kosherbacon8087]

Bob, you can now get powder coated screws in different colors. They sell them in black. These would be great in here rather then the stainless.

[@hand_emoji8280]

Love the intro transition keep up the good work bob

[@markwilkinson2250]

Great introductory transition pushing down the door and landing on the finished product. Well done video.

[@WinstonMakes]

With the right angle stock in the bandsaw, nest time you can try using a 1-2-3 block as a spacer to clamp against the flat of your stock.

[@TARWCreations]

These look awesome!! Perfect timing because I need to build a gate and want to do a "heavy duty" look so ill definitely be copying/adapting this to suit 😁

[@michaelpotase]

Nice really dresses up the new shop

[@kalebbranch5435]

That transition in the beginning was dope

[@austina2020]

Hi-Bye Butterfly @11:40 makes this video a true masterpiece. S/O Forby

[@WreckDiver99]

I like the idea of using the gutter for the trim. Clever.

[@ianmacdonald5195]

Good stuff. Heads up for anyone using cedar pickets like this; they generally come from the mill green so there's going to be a fair bit of shrinkage that'll be pretty obvious when placed edge-to-edge. If that's a concern, take the necessary precautions.

[@gary_sa_uk_be]

Love the podcast. I follow all 3 of you. Heard you guys talking about the doors and was excited to see your take on them. Thanks for sharing all your “making”! It really is a great wealth of information. Much appreciated by this fellow trying to find time to use my tools 😉

[@Iliketomakestuff]

Thanks so much for listening!!

[@TremendouslyAngryRon]

Love the podcast. Just found it a few months ago. Lots of great lessons learned from the discussions. Oh, and by the way, the barn doors look great!

[@dylyjay]

I love the music in your vids man!!! It hecking ROCKS🤘🤘🤘

[@forby_]

🎸🤘🔥

[@johnhill9583]

I found your channel a few weeks back while trying to learn how to do something. Since I have been hooked. I love your work! Keep it up! I wish I could do the same types of things. Now that I am nearing retirement maybe I can start having fun too!

[@brandon2076]

That opening transition was awesome.

[@GTAMASTER2216]

These intros keep getting better and better !

[@GTAMASTER2216]

Awww man thank you so much for liking my comment. That has made my day now 🥰

[@franskamstra2728]

Just a little tip for grinding those welds. Use the flat sanding disks with a backing disk. The grind way fasted than a normal thick grinding wheel. And even makes a smoother finish than the hard disks

[@jacobtanner4000]

I just learned a whole lot! Especially that bit at the end about the diagonal and compression. That’s super helpful! Thanks guys!

[@Iliketomakestuff]

Excellent Jacob! Glad to hear it!!

[@armata6530]

Sick intro transition

[@KingKevin108]

We really, really need a mirrored "Problem Solved" shirt

[@forby_]

😄

[@grahammoss5373]

Really smart doors. Thumbs up from sunny NZ

[@GRichardWrotten]

Nice! Smart thinking with the gutters!

[@christopherdahle9985]

14:30 diagonal braces are exactly correct. The thin metal straps need to be in tension as you have them and the wood, running in the opposite orientation, is in compression. If your doors sag, it won't be because of the orientation of the diagonal braces! Anyway, beautiful work.

[@loganc4233]

Awesome! Thanks!

[@nicholasleone5302]

caulk the flashing to keep water out especially the top.

[@joecaldera5438]

Great job! Love them doors!

[@ianglasson8068]

When cutting the reverse 45 deg angle - put a piece of square or rectangular section under the piece you are cutting to clamp onto.

[@josepherwin8709]

Bob, when cutting angle sections upside down like that, I’ve always used an off cut from a piece of box-section to clamp in with it. I use a rectangular section so it won’t interfere with the inside curve, but is wider than the top flange of the angle so that it clamps securely. If you don’t have a piece of steel that fills the requirement, use a piece of wood. I’ve used a chunk of 2x4, and it works too. It just needs to be able to fit in the saw clamp and hold tight.

[@randomblackguy21]

New editing skills are amazing

[@Iliketomakestuff]

That's Forby, he's been editing for a LONG time and is really good at it!!

[@forby_]

🙏

[@JeffTorgerson]

Nice work! Those doors look amazing. Also, a good tip on using gutters for trim/flashing. I had not thought about that before.

[@Sonal_Mobile]

Great work guys! I like how you troubleshooted the frame angles

[@maxmoreno5511]

this channel is really motivating. Glad I came across it. 😊😊

[@bikalimark]

i appreciated that shot at 2:07

[@abaddon101]

Every video the editing gets better. That intro was amazing!

[@loganpeters2626]

That was a really cool transition in the beginning

[@Iliketomakestuff]

Thanks!

[@jerryjohnsonii4181]

Awesome barn doors !!!!!!! Also thanks for the knowledge Sir

[@FredMcIntyre]

Awesome work Bob! 😃👍🏻👊🏻

[@tylerpeters1181]

This old house did a segment on flashing out windows. Tommy made a metal break out of 2x4's. That is another option for you.

[@JasonExplainsThings]

Those are rad Sir.

[@Iliketomakestuff]

Thanks!

[@SouthernStyleDIY]

Those doors look amazing!! Great upgrade

[@juliansnow693]

Love your videos man, much love from another Kentuckian

[@thewoodworker1703]

*Brilliant*

[@Maker_of_Things]

I watched you put the diagonals in and for a moment I thought "Check those are the right way around!" but then it is steel which is fine in tension so that is ok. If you turn them over then the thin steel flat bar might flex and let the door sag a little. So welded steel diagonal works great in tension, wooden diagonal only works in compression. Nice doors too, and only a little envious of your space there.

[@Iliketomakestuff]

Yeah, I could see both pros and cons of either direction with steel. I figured I'd just see how they hold up and adjust if needed 👍🏼

[@Maker_of_Things]

@@Iliketomakestuff I think they look fine that way, and I am sure won't cause you any problems at all. :-)

[@nickyoung6431]

When I did my apprenticeship we were always taught when cutting angle iron the way you did when you flipped it over, to put a scrap piece of RHS underneath to give you more surface area on the face to clamp to

[@dscraft6358]

Nice project! The doors looking great! 😊

[@edgardoheffele3]

I've been follwing your channel for years now, commented, share and all the stuff in the videos and I have to say. That intro. That intro was F-EPIC

[@Iliketomakestuff]

Thanks so much! I really appreciate it!!

[@willskookogey5232]

Could you do a bits video on different kinds of screws/bolts? I feel like that would be pretty useful. Keep up the great work!

[@raraavis7782]

Those sure are some stylish barn doors 👍

[@AlphaOmegaCreations1]

Love the intro👍

[@rjc1579]

Love the podcast plug! If you guys love ILTMS, you'll love the podcast!! Give it a listen.

[@chaseowens1122]

Just got to your question on the podcast - with wooden gates/doors the z is the opposite of what you have so that triangle holds the furthest point of the panel in square. There’s an inexpensive book called the “Fence Bible” you should check out that explains fences and gates in all material types. My guesstimate is that with steal it would be better to do it this way. If you had used tubes steel I don’t think it’s necessary.

[@mattiapassera5084]

What a beautiful door! The quality of the projects and the quality of the videos has grown substantially! Keep on doing great stuff Bob!

[@Iliketomakestuff]

Thanks so much!

[@thebeautyoflife327]

Loved that intro!

[@MikeTheMaker1]

That was the best intro yet!