Door Progress

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building a door DIY barn door wood bamboo sliding barn door

 

Movie Room Teaser

We can’t reveal the whole door all at once! Need to keep the theatrical suspense and drama going. For theme’s sake… We officially finished everything just last night, and got to christen in the movie room with all the roommates. Unfortunately it was late and dark, so Joe’s taking some better “after” photos today. If the rain lets up we may even get graced with a hint of natural light. Start here for the beginning of our door, and here for the finished product.

But until then, we have a lot of the build to share with you guys. We did this door in fits and starts, but it definitely took a lot of time and energy overall. We both agree, this project scored two thumbs up 🙂

Where were we?

I think when we left of we had just bought all of the flooring. Flash forward – We decided to use a piece of plywood and glue the boards to either side. Making the door a bit heavier, but our work a little easier. Adding a core gives a bit of stability to the whole thing as well.

measuring building a door DIY barn door wood bamboo sliding barn door

We determined the dimensions of the doorway and marked the plywood accordingly.

measuring and cutting plywood for DIY sliding barn door laminate wood flooring

We cut it to size and got to work with the floor boards.

tongue and groove measuring and cutting plywood for DIY sliding barn door laminate wood flooring

This task involved a lot of snapping together of the tongue and groove boards, and flushing them up against a T-Square.

brick pattern

We made a staggered pattern like this.

measuring and cutting plywood for DIY sliding barn door laminate wood flooring

We did one side at a time, and determined that we needed to cut a handful of pieces in half. Luckily we were able to repurpose the tops/bottoms and had just enough wood.

measuring and cutting plywood for DIY sliding barn door laminate wood flooring

Now since these have tongues/tabs on one side, we needed to cut off some to fit with the repurposed end pieces that we had to cut in half.

dremel tool measuring and cutting plywood for DIY sliding barn door laminate wood flooring

Otherwise it was like trying to put a peg into the end we leveled off. No notch = no fit.

measuring and cutting plywood for DIY sliding barn door laminate wood flooring

And then rinse and repeat on the reverse side.

Let’s Get Gluing

gluing laminate wood flooring to plywood for DIY sliding barn door

Think this is too much glue?

liquid nails gluing laminate wood flooring to plywood for DIY sliding barn door

Liquid Nails

gluing laminate wood flooring to plywood for DIY sliding barn door

It really lives up to the name!

gluing liquid nails laminate wood flooring to plywood for DIY sliding barn door

The reason we needed so much is because you have to be quick — This stuff only lasts about 45 seconds before requiring us to load a new tube.

how to glue liquid nails laminate wood flooring to plywood for DIY sliding barn door

We glued each side to the plywood.

gluing liquid nails laminate wood flooring to plywood for DIY sliding barn door

And very carefully, we evenly distribute weight around the door so it would dry without warping or welcoming in air bubbles.

gluing liquid nails laminate wood flooring to plywood for DIY sliding barn door dry time

We glued one side at a time to be extra precise.

trimming and sanding DIY sliding wood barn door laminate floor

Once it dried, Joe and Steve went to work tidying up a couple parts. The door was slightly wider than we wanted.

trimming and sanding DIY sliding wood barn door laminate floor

Remember all those awkward ends? We also had to hack off those tabs that stuck out on the top and bottom of the door. They just looked goofy with alternating tongues sticking up. Like a picket fence. (Not the look we were trying for.) Buh-bye!

trimming and sanding DIY sliding wood barn door laminate floor

They taped it up with painters tape to prevent any splitting.

trimming and sanding DIY sliding wood barn door laminate floor cutting bamboo

Wow, we found out how tough bamboo is! It’s a powerful plant and even more sturdy once treated and pressed together as floorboard!

Which side do you like best?

The dark Tigerwood or the Honey bamboo? Can’t wait to get the rest of the photos up for you guys! We’ve framed out the doorway, added an inset handle, put up the sliding track, and added trim work.   Are you following hockey playoffs like we are? I’d love to see a W on the big screen tonight. Go Wild!

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