How I Built My Custom Fluted Barn Door with Hidden Sliding Door Hardware

I had a vision for this door ever since I completed the accent wall in my bedroom 2 years ago. Once I stumbled upon the concealed sliding door hardware it all came together. In this post I'm going over how I built my door as well as answering the most commonly asked questions about it.

You can find all of the materials to build the door HERE.

Concealed sliding door hardware can be found HERE.

*links may earn me a small commission.

Step 1: Starting With the Basics

I began by heading to my local hardware store and having a ¾-inch sheet of plywood cut to the exact dimensions I needed for the door.

To give the plywood a clean, finished edge, I added edge banding (a piece of wood veneer with heat activated adhesive) along the sides. It's a really useful product for wood working because it's really easy to apply and it's easily stainable or paintable. This small detail makes a big difference in creating a polished, professional look.

Step 2: Adding the Trim

For the design, I chose a trim with a curved, fluted profile because it perfectly matched the accent wall I previously installed in my bedroom. I applied adhesive to the back of each piece and secured it in place with my pin nailer.

Some pieces were a bit uneven (I mean, when are they not?), but they straightened out easily as I nailed them down. I used a spacer (ok it was a book) to keep the gaps consistent.

Once all the trim was attached, I filled in any small gaps with wood filler, sanded everything smooth, and finished it off with primer and paint.

Step 3: Installing the Hardware

I really didn't want the look of traditional barn door hardware so I used a sliding door hardware kit. The hardware mounts to the wall behind the door and there are wheels on the bottom that help support it's weight. The hardware is made for specific types of doors so I had to make a few adjustments in order to make it work for my design.

Instead of insetting the track as the instructions suggested, I mounted it directly to the back of the door. This gave me the extra clearance I needed to account for the trim on the wall where the old door used to be. The track then slides along a mounted piece on the wall.

The kit also included support wheels to help bear the weight of the door. Instead of insetting them, I attached a 1x2 board to the back of the door and mounted the wheels directly onto that piece. It took a bit of trial and error to figure out where to mount the wheels.

To keep everything steady, I used the floor guide that came with the kit. I also added a small piece of trim around the guide to help the door stay in place when sliding open and closed.

Step 4: The Finishing Touch

From the inside, the door looks sleek and clean, and from the outside — it’s a showstopper. The fluted trim gives it a modern, textured feel, while the mirror takes it to the next level. It’s both beautiful and practical — the perfect combination for any space.

Most Frequently Asked Questions

Does the door open all of the way?

Yes and No. There are different size hardware kits that you can use for different door openings. Unfortunately, I should have made the door a little bit larger to accommodate the actual opening of our doorway. I ended up having to use a smaller hardware kit so NO my door does not open all of the way but YES it can if you plan better than I did. It opens about 95% of the way so it isn't really a hindrance for everyday life.

How does the door slide on the carpet?

The door slides fine on our carpet but I would imagine that it does slide easier on hard flooring. To be completely honest, we leave the door open most of the time since I renovated our primary closet (check it out here!) My biggest complaint about the hardware is that I don't love the soft close mechanism. Overall, between the soft close feature and the carpet, it doesn't slide as smoothly as I would like it to.

How does it look from the side?

From the side you can see the trim on the wall. But from any other angle you can not see it. Had I made the door slightly larger, you wouldn't be able to see it at all.

What is the size of your door?

The door is 34" x 87" while the door opening itself is 28" x 80.5".

Does the door lock?

No, I didn't add any kind of locking mechanism since it only enters our closet. There are barn door locks available like this one HERE

What color did you paint the door?

The door is painted Colonnade Grey by Sherwinn Williams. It's a really pretty beige-grey color.

If you love the look of the modern barn door but aren't interested in making it yourself, I've linked a few premade options HERE.

Check out a video tutorial below.