My neighbors purchased hardware for a barn door over a year ago. Their plan was to find a door they could re-purpose. They couldn’t find anything large enough that didn’t cost over $2000. Neighborhood Craftsman to the rescue!
I made this double-sided herringbone barn door off with 10 repurposed pallets. I found some with great pine, oak, maple and cedar (these are what I could identify, more on how to identify the different types of pallet wood).
After using my new pallet buster (where have you been all my life) I pulled all the nails and ripped and planed the pieces to desired sizes. I then cut them into pieces to place in the herringbone pattern. Each piece is 10″ long and 2 3/4″ wide and 1/2″ thick.
This door is 2 sided and the work involved was nothing short of 2 doors. I had to work one side at a time. I started with 1/2″ plywood and framed it in with a 1×4 material. It was also planed to the same thickness as the planks. The border was glued and clamped overnight.
Once dry I started placing the pattern. I sorted the planks into like colors and grain so I could have a random pattern. I cut all the edge pieces with my chop saw and once I was happy with the pattern I pulled them up a section at a time and glued them down. I let it dry for a day and sanded any rough spots. I then flipped it over and repeated the process.
The border was stained with Jacobean from Minwax, the pattern has a few coats of Tung Oil and then a coat of semi-gloss poly was added.
The final door measurements were 40″ wide and 84″ high. It is 1 1/2 inches wide.