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You can use a variety of wood to build a barn door, but the most common options include 1-by boards and 2-by boards for the backing and the decorative boards on the front of the door. Softwoods like pine will save you some money and should hold up well, while hardwoods like maple and oak will stand up to more wear and tear. You could also build the backer out of plywood to minimize the cuts you need to make. Whatever you decide on, make sure the width of the wood is compatible with the mounting brackets you buy.

It’s possible to install a door yourself if the wall opening already exists, but the work is rather complicated, and a professional installation is usually well worth the investment. For your door to work and close properly, you’ll need to shim and level the door frame in your wall perfectly, which can be difficult. Additionally, we recommend you always hire a professional door installer to place an exterior door, as mistakes during the installation process can lead to poor security for your home.

For most doors, you can use a 1-inch chisel to create the mortise for the strike plate. In addition, you can use a 3/4-inch chisel for more refined cuts and to clean up the edges of your mortise. The smaller tool is handy when squaring off the edges around the hole for your latch.

Most modern, standard doors are 1 ⅜-inches thick, so you should aim for this thickness unless you're building a door to replace an antique door or fit into a non-standard wall opening. Thickness varies when installing a pocket door or sliding barn door, so a good rule of thumb is to measure your existing door, if possible. For standard doors, you can also measure from the inside of the door to the door stop to gauge the proper thickness.