This Prodigious Pallet Barn Door Set measures 80″ tall and a total of 40 1/2″ wide. We needed so much wood that was the same thickness, which we went directly to a provider.
The boards were seasoned boards that simply didn’t make the cut to arrive at the assembly line.
A bit more about our Prodigious Pallet Barn Door Set:
To begin, we used a sheet of plywood as the frame to nail the boards to. We applied a layer of boards to create the frame, placing boards side-by-side to make the frame appear thick and sturdy. Then, we added a second layer to create the thickness and the illusion of recessed panels. Next, we installed more boards into the panel area. To finish the front sides, we applied cross-pieces diagonally.
We repeated the process on the back sides so that the doors will be beautiful on both sides.
Prodigious Pallet Barn Door Set – the finish:
We sanded the boards lightly, just to remove any splinters or lifted grain areas. There was no stain or protective coat added per customer request but could be added easily. The outcome is two massive beauties that we’re quite proud of.