How to: Barn Style Pantry Door

Today I am making a Pantry door to cover all our stuff. Thank you for following along. I used 6- 1x6x8 to build this door (80"x24"). Here is how i did it:

1- Cut 5 pieces to 80", which is the height of the opening.

2- Ripped the pieces to 4" 7/8 inch. The opening is a little smaller than 24". I want my 5 boards to equal the size of the opening minus 1/8 inch to allow for an even gap.

3- Glue the pieces to form a big panel. Glue is extremely strong. Add clamps. The key here is to keep your panel as flat as possible during the gluing process to avoid spending a lot of time in the next steps.

4- Plane the panel by any means necessary. I used my hand plane to do the majority of the work and then sanded the whole things to 120 grit with my orbital sander.

5- Cut panel to size. In my case a little over 80" taking into consideration the 1/16 inch gap in the top and bottom.

6- Ripped another 1x6 to 2" to make the top, bottom and cross piece. Cut to size two pieces and glue them up. One on the top of the panel, one on the bottom. 

7-  Cut one cross piece to fit in between the top and bottom pieces. I cut a 22.5 degree angle and cut slowly until it fit in between the pieces nicely.

8- Stain and finish to your liking. :)