How to Build a DIY Barn Door With a Shiplap Design

Step 1: Measure and Cut the Frame

Measure the dimensions for your barn door. Standard sizes are 36" x 84" or 42" x 96", but adjust as needed. Use a circular saw or miter saw to cut the 1x3 pine boards to create the top, bottom, and side frame pieces according to your measurements. Ensure all pieces are cut at 90-degree angles.

Step 2: Assemble the Frame

Lay the top and bottom frame pieces parallel to each other on your work surface. Position the side frame pieces vertically, forming a rectangular frame.

Apply wood glue to the ends of the side pieces and attach them to the top and bottom pieces. Use a carpenter's square to ensure the frame is perfectly square. Secure the frame with 1 ¼-inch brad nails.

Step 3: Add the Shiplap

Lay your frame on your work surface with the front side facing down. Apply wood glue to the back of the shiplap boards.

Position the first shiplap board flush with the top of the frame and secure it with brad nails.

Continue adding shiplap boards, ensuring they are tightly joined. For the final board, place it in the middle to serve as a visual guide.

Step 4: Sanding and Prep

Use various grits of sandpaper to smooth any rough edges and imperfections on the front and sides of the door. Pay special attention to the corners and edges to create a distressed, rustic look if desired. Don't forget to wear safety goggles, ear protection, and a dust mask during sanding.

Step 5: Staining or Painting

Choose a stain or paint color that matches your design preferences. Apply the stain or paint evenly to the front and sides of the door using a paintbrush or rag.

Allow it to dry completely according to the manufacturer's instructions. Apply additional coats if necessary to achieve the desired finish.