I'm bidding on a job that calls for a hanging barn door. The wood should have that reclaimed look.
First question - is soft maple a suitable wood to use?
I am thinking of using soft maple that I turn into "reclaimed" by physically distressing the surface with a wire wheel, and then using ferrous sulphate and other methods to age the wood. They don't want it crazy beat up and stained dark. More a driftwood feel.
Second question is about construction. The doors will be 36" x 97" each.
I figured on making a frame 1" thick. The stiles could be 2 - 2 1/2" wide, the rails 3" wide.
I would have a rail top, bottom and two more in between.
This frame would be sheated on both sides with approx 3/4" thick "reclaimed" wood, layed up horizontally.
This will put the finished door at about 2 1/2" thick.
To avoid any chink of light through the door, however unlikely, I can fill the frame with foam sheeting before sheathing it.
That's about it. Any advice?
thanks, Mark