The sliding barn door, it’s become a favorite of many and a trend that seems to be sticking around for awhile. I built this sliding barn door console and also made the hardware too because when you DIY you can make it exactly how you want.
Today I’m sharing how to make your own sliding barn door console hardware using off the shelf supplies from the hardware store. Also known as DIY hardware for your sliding barn doors.
This DIY sliding barn door console was my knock off project submission for week one of Creating with the Stars last Spring and it took first place! I’m finally getting around to sharing how I built the console including the hardware you can build it too AND for a fraction of the retail cost.
This post contains detailed information on the sliding barn door console HARDWARE with links to free plans you can download and print.
My build was inspired by Sundance Catalog’s Yorkville Sliding Door Console:
The retail version above sells for $2800 plus shipping – yikes! I’ll show you how to make your own DIY version for $300.
The barn door hardware is actually a collection of basic hardware pieces you can find at any big home improvement store – aluminum bars with 1 1/2″ pulley wheels.
Ana White recently shared my interior cedar shutter plans over at her place and this console is in those pictures which got a lot of readers interested so I thought it was time to post the plans.
Below are details on the hardware used to create the sliding barn door console doors:
- 1 – 1″ L shape angle aluminum bar x 1/8″ thick x 96″l (base track)
- 1 – 1″ flat aluminum bar x 1/4″ thick x 96″l (hanging track bar & vertical door bars)
- 4 – 1 1/2″ awning pulleys
- 3 – #12 x 2 1/2″ metal screws
- 3 – 1″ steel spacers
- 24 – 1/4″ washers
- 7 – 1/4″ hex nuts
- 4 – #12 x 1 1/2″ metal screws
- 8 – #12 x 3/4″ metal screws
- 1 – L shape aluminum bar @ 60″l (base track)
- 1 – flat aluminum bar @ 62″l (hanging track bar)
- 4 – flat aluminum bar @ 8 1/2″l (vertical door bars)
Step 1: Cut the bar pieces as listed above. I highly suggest an angle grinder if you have one. Be sure to smooth any sharp edges using steel wool.
To make the cuts I used a combination of a coping saw, dremel drill, metal rasp and steel wool. Definitely consider using a Dremel saw-max or an angle grinder, it will be much easier but I didn’t have those tools at the time so I made it work using what I had on hand.
Step 2: You need to remove the pulley wheel from inside the pulley mechanism. This will not be fun. I used my dremel to slice off the center ‘button’ on both sides of pulley then clamped it down and hammered away at the center pin using an old drill bit:
Tip: the pin will come out faster if the metal is cold (put the pulley in the freezer).
Step 3: Spray paint all the metal pieces (I choose not to paint the screws & washers) using oil rubbed bronze.
Step 4: Attach the base track first. Center the track and set the door in the track to be sure you have enough sliding space. Predrill and use 2″ wood screws down into base moulding.
Step 5: Attach the hanging track 1.75″ from top. Mark the face frame and predrill holes all the way through the frame.
Set up the hanging track hardware in the order pictured above.
Step 6: Secure the hanging track to the face frame with the hardware in the following order: screw, washer, track, spacer, nut.
Step 7: Create the door hardware. Again layout the hardware in the order pictured above: screw, washer, flat bar, washer, pulley wheel, washer nut. Predrill the flat bar in 3 spots (2 holes to attach to door, one hole above for wheel mechanism).
Place door in base track then lift 1/4″ or add a spacer, you need bottom clearance for the door to glide. Now place wheel (attached to flat bar) in track and see where everything lines up. Use dimensions below as a guide:
Step 8: Predrill holes in door front for remaining 2 washers and 3/4″ screws then attach. Repeat process for other side, be sure door is level.
Step 9: Hang doors onto track. The hex nut will allow you to adjust the tightness of the rolling wheel and enables you get past the middle screw head on the hanging track.
SHOP THIS PROJECT: