Sliding Barn Door Dresser

Transcription

1 Supply List Sliding Barn Door Dresser Copyright 2015 Item Quantity Description 48 x 96 x 3/4 plywood 3 48 x 96 x 1/4 plywood 1 1 x 12 x 10 1 Pine or whitewood board 1 x 6 x 8 7 Pine or whitewood board 1 x 4 x 8 4 Pine or whitewood board 2 x 6 x 8 2 Pine or whitewood board 2 x 4 x 8 2 Pine or whitewood board 1 x 3 x 8 1 Pine or whitewood board 1 x 2 x 8 8 Pine or whitewood board 1-1/2 x 12 x 1/4 steel flat bar 4 1-1/2 x 71 x 1/4 steel flat bar 1 1-5/8 piece of 1 dowel 2 3 garage door pulleys 2 3/8 flat washers 26 Spacers for the pulleys 3/8 x 2-3/8 hex bolt 6 3/8 x 4 hex bolt 4 3/8 lock washer 8 3/8 hex nut 8 Brad or finish nails 1-1/4 pocket hole screws /2 pocket hole screws 35 handful

2 Be sure to check your scrap bin for material before purchasing anything as you may already have enough scrap to save yourself some money. These measurements are exact for this model. Measure and cut as you go to make sure everything lines up perfectly with your project. Read and understand the entire plan before beginning the project. Drill pocket holes for 1-1/4 screws in the plywood as indicated by the arrows. Sliding Barn Door Dresser - Page 2

3 Drill pocket holes for 1-1/4 screws in the 1x material and 2-1/2 screws in the 2x material as indicated by the arrows. Sliding Barn Door Dresser - Page 3

4 You might be able to save some money by purchasing the steel flat bar from a local metal supplier or a local welding shop or you could purchase a pre-made sliding barn door kit if you prefer. The following diagrams represent the steel flat bar needed to make this sliding barn door. All of the steel flat bar is 1-1/2 wide and 1/4 thick. Drill 3/8 holes as indicated by the dimensions. With everything cut and drilled you can clean the metal and apply a paint of your choice. The two holes on the 71 piece are each 2 from the ends. For the 12 pieces use the following dimensions. Sliding Barn Door Dresser - Page 4

5 Using wood glue and 1-1/4 pocket hole screws attach the top and bottom braces in front and back. The back braces are inset by 1/4 to allow room for the back panel later. All pocket holes face the outside. Secure the lower shelf with 1-1/4 pocket hole screws from the bottom panel into the sides and from the lower braces into the bottom panel. Cut the appropriate size notches to allow a 1 x 4 board to cover the bottom front brace. Secure it with wood glue and nails from the inside. Sliding Barn Door Dresser - Page 5

6 Attach the top support boards with 1-1/4 pocket hole screws. These are evenly spaced and flush with the top of the top braces. Assemble the front face frame. The drawer dividers are evenly spaced. Attach the front face frame with wood glue and brad nails or finish nails. Sliding Barn Door Dresser - Page 6

7 Attach the three rear vertical 1 x 2 boards. The center board is centered left to right with it s wide face facing the back. Attach it with 1-1/4 pocket hole screws. The left and right boards are attached to the sides with wood glue and brad nails with the narrow face facing the back. Add the center divider and secure it with 1-1/4 pocket hole screws so that the pocket holes face the drawer area and the pocket hole side is flush with the inside of the drawer area. Sliding Barn Door Dresser - Page 7

8 Line up the steel flat bar 3/4 above the bottom of the 1 x 6 face frame piece. Mark and drill the necessary 3/8 holes in the face frame for securing the steel flat bar. Then cut four 1-5/8 pieces of 1 dowel and drill a 3/8 hole in the center. These will be large washers to hold the flat bar away from the dresser. Use two 4 bolts and two dowel washers to secure the flat bar in place with one flat washer, lock washer, and hex nut on each bolt inside the dresser. Secure the front 1 x 2 trim board to the front of the shelf making sure the top surfaces remain flush. Then use a jigsaw to notch out the necessary amount to fit the shelf into the dresser. Center the shelf vertically and attach it to the dresser with 1-1/4 pocket hole screws Sliding Barn Door Dresser - Page 8

9 Attach the side guides into the right side of the drawer area. These will keep the drawers tracking properly. Use wood glue and brad nails to secure them. Start assembling the 1 x 2 drawer glide frames by attaching two 1 x 2 strips on each side in line with the front horizontal pieces in the face frame. Attach these with wood glue and brad nails. Then attach the back 1 x 2 strips with wood glue and 1-1/4 pocket hole screws. This forms the frames that will hold the drawers. Sliding Barn Door Dresser - Page 9

10 Attach the center 1 x 2 boards to the top of each drawer opening. As each drawer is pulled out these will prevent the drawer from tipping forward. Secure them with wood glue and 1-1/4 pocket hole screws. Attach the back panel with wood glue and brad nails. Sliding Barn Door Dresser - Page 10

11 Assemble the drawer boxes with wood glue and 1-1/4 pocket hole screws. Then attach the bottom with wood glue and brad nails. Trim the 1 x 12 front panel boards down to 1/8 less than the height of the drawer opening and 1/8 less than the width of the drawer opening. Then attach them to the drawer fronts with wood glue and either 1-1/4 wood screws or brad nails from the inside. Finally, either cut a matching handle into each drawer with a jigsaw or use a large hole saw to drill a circle hand grab into the front of each drawer. Then install the drawers. Sliding Barn Door Dresser - Page 11

12 Attach the top boards with wood glue and brad or finish nails. Assemble the sliding door panel with wood glue and 2-1/2 pocket hole screws. At this point sand and finish the entire project as you wish. Using the 12 flat bar pieces locate and drill the mounting holes through the door panel. The flat bar should be 3-1/2 from the sides of the panel and should extend 7-3/4 down from the top. The two holes that are 4-1/2 from each other are the two that are bolted to the door. Sliding Barn Door Dresser - Page 12

13 Determine how many 3/8 washers are required on both sides of the pulleys to evenly space the pulley in the center of the door. One lock washer and hex nut is needed on the back side as well. Then remove the pulley and bolt to prepare to hang it. With the pulleys removed slide the door into place from below. Use a piece of 2 x 4 scrap material on the floor to elevate the door as you install the pulleys. If you find the door to lean in or lean out you can adjust the washer spacing to shift the pulley in or out on the bolt to correct any leaning. As always, be sure to show off your completed project in our Submit Your Project section on our website!! Sliding Barn Door Dresser - Page 13