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Thread: Barn door panel insert

  1. #1

    Barn door panel insert

    Hi there. New to the forum, semi-skilled woodworker. I am making a barn door for my house using 1 1/2" red oak for the frame and 7/16" oak to make the panel insert that will go in the frame.
    My question is, what should I use to keep the panel in place and allow for expansion? I can't find space balls that are large enough as they seem to be mostly for cabinet doors and are .26" diameter.
    Any advice would be greatly appreciated.

  2. #2
    Join Date
    Mar 2003
    Location
    San Francisco, CA
    Posts
    10,329
    You don’t need space balls. At the middle of the rails, drive a nail through rail and the panel. Of course, center the panel first.
    Doors were built like this for many years, long before spaceballs existed.
    Last edited by Jamie Buxton; 09-09-2023 at 10:31 AM.

  3. #3
    Join Date
    Sep 2009
    Location
    Atlanta, GA
    Posts
    6,432
    What size is the panel? What’s your ideal diameter for the space balls?

  4. #4
    Join Date
    Aug 2012
    Location
    Missouri
    Posts
    2,152
    Pieces of rubber tubing or backer rod for caulking. Many sizes to pic from.
    Jim

  5. #5
    Join Date
    Nov 2014
    Location
    Allentown, PA
    Posts
    188
    There's an advantage to backer rod: Wind won't blow through the crack, like it does in my circa 1850 doors.

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