So with the weather still snowy and cold over the weekend, and no ability to work on the chicken coop or recycled greenhouse project – it was time to cure the winter blahs with a building project! And yes, as the garage became a temporary workshop, sadly Mary’s vehicle was once again the victim and banished to the driveway.

barn door headboard
The idea came from the barn doors we built from old flooring for our barn

The headboard can be made with a variety of materials.  If you want a rustic look – you could easily use pallet boards and old barn wood to create it completely from recycled materials.  It can also be built from simple framing lumber. Ours is a combination of both, along with some salvaged barn hardware saved when we deconstructed two old barns.

Since this was built for a king sized bed – we built it as two separate door frames and then attached them together once in the bedroom. It made it easier to move and work with, not to mention fit through tight hallways!  When finished – it measured 6′ high x 83″ wide.

Here are the basics on how we made ours:

Door Materials:
(4) 2 x 6 x 72″
(3) 2 x 4 x 80″
(4) 2 x 10 x 29″
(2) 2 x 4 x 29″
(12 to 16 pieces) of 3/4″ or 1″ thick, 48″ long boards
Tongue and groove wood, old barn siding or pallet wood would work great for this, we used some 3/4″ x 8″ wide tongue and groove boards we bought at the lumber yard for around $40.

Trim Boards:
(2) 2 x 4 x 72″
(1) 2 x 4 x 85″

Tools Used:
Tape Measure, Circular or Chop Saw, Drill, JigSaw, Nail gun, (30) 2 1/2″ screws, Biscuit Joiner (overkill)

IMG_0258
We cut all of our pieces to length to start, including the cured cuts for the top of the doors.
We then laid out the frames on the floor upside down.
We then laid out the frames on the floor upside down.
IMG_0283
We attached the tongue and groove boards to the back of the frame with a nail gun
We added 2 x 4 trim boards to each side and the top for extra detail
We added 2 x 4 trim boards to each side and the top for extra detail
We added a single coat of stain, and it was time to attach the old barn hardware
We added a single coat of stain, and it was time to attach the old barn hardware

Step 1 – Cut Materials
We started by cutting all the materials to length – using  a mixture of scrap lumber and purchased wood from the local lumber yard. Scrap wood is actually a great choice, even if it is nicked up – adding a rustic feel to the finished piece.

Step 2 – Making The Top Curved Boards
Taking the two 29″ 2 x 10″ pieces – we traced a long curved line on one and cut it out with the jigsaw.  We traced the cutout to the second board to match, and made our second cut.

Step 3 – Laying Out The Doors:
Next, we assembled the two doors – one at a time. We built the doors face down, assembling it from the back.

We started with (2) 2 x 6″ x 6′ rail pieces. We then laid  (2) 29″ pieces between the 2 x 6″ side rails for the doors. We put the curved board at top, flush with the top of the 2×6’s.  We placed the other 29″ board  24″ from  the bottom of the door , and the remaining 2x4x29″ board  42″  from the bottom.

Step 4 – Gluing the Frame:

I applied glue to all of the joints and clamped them together while nailing on the backing boards.  I did take an extra step and added simple biscuits to the joints for added strength  – It’s a habit of “overbuilding” that I tend to have :).   Simply applying glue to the joints and clamping would have been enough, especially with the backing boards and 2 x 4″ braces we attach later.

Step 4 Assembling the Door

Using a 2 x 4 as a guide on the outer edge of the back of the door frame – and with a nail gun, we nailed in all of the 48″ tongue and groove boards across the door opening – nailing on the top and bottom, and to the 29″ 2 x 4″piece as well.  You could use pallets or reclaimed boards here just as easily. By nailing in to the door frame boards, the door becomes one solid piece.  Once done, we repeated the process and built door #2.

Step 5 – Assembling The Headboard:

We took both doors to their permanent location before assembling into the final headboard. Placing both doors side-by-side with the fronts facing the wall – we screwed in the top 2 x4 x 80″ piece to connect the two doors.  Then we installed the remaining two 80″ boards – one at the very bottom and one at the bottom of the 2 x 10 x 29″ board located below the tongue and groove boards.

Step 6 – Trim and Hardware:

Next, we flipped it around, and added a couple of 2 x 4″ trim boards on each side as well as the top to trim it out and give a little depth.  All that was left was to stain, and add the old barn hardware.  We finished it off with a couple of old lanterns, and the headboard was complete!

From start to finish – the entire project took about 4 hours.  Well, 4 1/2 if you count cleaning the garage back up ๐Ÿ™‚

If you would like to receive our weekly DIY and Gardening Posts โ€“ be sure to sign up to follow our blog via email, Twitter or Facebook in the right column

– Jim and Mary

The doors with lanterns and reclaimed barn track pulleys attached
The doors with lanterns and reclaimed barn track pulleys attached

30 thoughts on “How To Build A Rustic Barn Door Headboard

  • November 2, 2015 at 9:57 am
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    I love this project and will be making this for my guest bedroom. Where did you find or where can I find the hardware to hang the lanterns and also the metal pieces on top of the headboard

    Reply
  • March 14, 2015 at 1:35 am
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    This headboard is magnificent. What is the black plate looking thing in the middle?

    Reply
  • February 22, 2014 at 10:15 pm
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    I think this bed is stunning! What color stain did you use? It looks like you stained the inside wood a lighter color than the outside?

    Reply
    • February 23, 2014 at 7:05 am
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      Thank you Michelle – we did at first – and then decided it looked better all stained with the darker walnut stain.

      Reply
  • October 6, 2013 at 8:57 am
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    My wife loves this! I’m part way in to building this and I’m trying to figure out the best way to clamp the frame while the glue dries. Can you offer any input on how you clamped it?

    Thanks!

    Reply
    • October 6, 2013 at 9:57 am
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      We used long pipe clamps but you could also use ratchet straps.

      Hope this helps, and let us know how it turns out.

      Reply
  • July 28, 2013 at 3:42 pm
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    how did you fasten to the bed? or did you fasten it to the wall?

    Reply
    • July 28, 2013 at 6:48 pm
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      Hi Norm – It can be fastened to a typcal metal bed frame with thru bolts – but for ours – we just secured it to the wall with a few screws. – Jim

      Reply
  • July 14, 2013 at 1:45 pm
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    Any idea on the measurements you would use for a full size bed instead of king size? Thanks

    Reply
  • April 28, 2013 at 9:38 pm
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    I am so glad that I found your blog! My son wants his bedroom to be as rustic and western as possible! We have found barn door beds for sale, but for the price we wanted to build it ourselves. This is perfect! Thank you so much for sharing!!! We will be starting our project very soon! ๐Ÿ™‚

    Reply
    • April 29, 2013 at 8:03 am
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      We are glad you found us to Sara! It really is a simple project and saves so much money! You will have to send us pictures when you are finished! Jim and Mary

      Reply
  • April 12, 2013 at 12:22 am
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    what color stain did you use? this is awesome

    Reply
  • February 25, 2013 at 11:09 pm
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    Very pretty! We want to make a headboard for our kingsize bed so I keep my eye out for ideas.

    Reply
    • February 26, 2013 at 6:26 pm
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      Thank you Abbi! Its actually surprised us how easy it was to complete – good luck on making yours! Jim

      Reply
  • February 25, 2013 at 7:49 pm
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    These are stunning! We are so not handy (sadly!) but I just love anything reminiscent of an old barn.

    Reply
    • February 26, 2013 at 6:27 pm
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      Thanks so much for the compliment! We love anything to do with old barns too!

      Reply
  • February 25, 2013 at 2:13 pm
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    I love it. That is gorgeous. I’ve seen a ton of those beautiful ideas on pinterest – it’s nice to see someone make it a reality! (Oh, I suppose those original pinners did, too. I just never clicked that far.) Yours looks great.

    Reply
  • February 23, 2013 at 8:24 pm
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    Very cool! I can’t believe it’s newly built, it seriously looks old and weathered. Perfect!! Your blog looks fun, and there is lots to look through. Glad I found you, and I love everything recycled, upcycled, and handmade. You guys do it all ๐Ÿ™‚

    Def pinned this awesome headboard, and am following along now ๐Ÿ™‚

    Have a wonderful day, and stop by anytime to say hello if you can.
    P.s. After coming back from an extended blogging break, I’ve started a 40 day challenge to get HEALTHY by my birthday. If you get a chance to check it out, I could sure use the support!
    Hugs, Bella ๐Ÿ™‚
    Bella’s 40 Day Challenge

    Reply
  • February 19, 2013 at 11:38 am
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    Talented!

    Reply
  • February 19, 2013 at 10:55 am
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    Really awesome. love your emails……

    Reply

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