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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.

Longer screws can make a door more secure, but this isn’t a foolproof method for security. Replacing the short screws in your door’s strike plate with screws that are 3 inches long will make it much more difficult for an intruder to force entry by kicking down the door, but it won’t do anything to stop them from picking the lock. 

A slab door is a standalone door without a frame or hardware. A prehung door is a complete set that includes the door, frame, hinges, and sometimes the doorknob and lockset.

In most cases, a prehung door is the better and easier option to install, especially for DIY projects or exterior applications, as they often come pre-weatherproofed. They require fewer tools and less experience to install properly. Although prehung doors are heavier and have a higher upfront cost, the investment is often worthwhile for a complete upgrade that includes a new frame.

A slab door may be a better choice if you are on a tight budget, have a custom-sized wall opening, or only need to replace the door while keeping the existing frame. While the initial cost is lower, you will need to purchase all the hardware separately and do more DIY work to hang it, which may not result in significant time or money savings.

While not strictly required, it is highly recommended to shim both sides of a door. Shimming both sides allows you to make minor adjustments for wall framing that isn't perfectly plumb, ensuring the door is level and hangs evenly. This practice helps the door swing open and close smoothly, reduces the chances of the frame warping, and can be used to center the door within the wall opening. If you are working alone, you may find it easier to remove the door slab to lighten the weight while supporting the frame and inserting the shims. With two people, the process is generally faster and easier, whether the slab is left in place or not.