Discover how a haunched tenon joint can give your barndoors unmatched strength and a clean, rustic look. This video walks you through the design, cutting, and assembly steps, plus tips for finishing that will make your doors the focal point of any space.
#Barndoors #HaunchedTenon #DIY #Woodworking #RusticDesign #HomeImprovement #FurnitureCraft #Handmade #BuildItYourself #Carpentry
#Barndoors #HaunchedTenon #DIY #Woodworking #RusticDesign #HomeImprovement #FurnitureCraft #Handmade #BuildItYourself #Carpentry
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00:00In this video, I'm going to show you how to build these barn doors.
00:05Okay, first thing we want to do is get some nice barn wood.
00:08This stuff actually came out of a barn that was built a couple miles east of here
00:12and was built in the 1900s and stood until about 2019.
00:16So it's old and it's got beautiful old saw marks on it.
00:20And the first thing we want to do is grab our metal detector
00:23and go over to this barn wood to make sure there's nothing hidden inside.
00:26When I take down the barns, I usually go through it all and make sure there's no nails.
00:29That's me just looking at it pulling nails out.
00:31But you do get nails sometimes broken off on the inside.
00:34So I go over everything with this Magic Garrett one,
00:36the same one that the airport security probes you with when you try to go somewhere on a trip.
00:42Okay, now we're not going to have any surprises getting nails in the planer.
00:45So I've got two doors to build.
00:46They're going to be full pass-through haunched mortise and tenon.
00:49And so my doors are 82 tall and 33 wide.
00:52My styles have to be the full 82 tall and my rails have to be the full 33.
00:58So I'm going to cut these down now just over the length of where they're going to be
01:01while I go through the planing and in case stuff chips off and stuff.
01:04I'm cutting everything a little bit long before we cut down to exact sizes.
01:07Okay, with all the boards cut to size, now we want to try and preserve as much character as possible.
01:21Since there's no such thing as straight barn wood and because I'm trying to preserve as much character as possible,
01:25meaning the saw marks and the age marks and stuff like that,
01:28I'm going to carefully set my jointer to the lowest depth possible
01:31and find the side of the board that I think I can get the flattest
01:36while preserving the most amount of character.
01:38So I'm just going to slowly pass it over and then keep looking at it
01:41until I get something that I can pass through the planer that has a uniform bottom
01:45and I can get my uniform thickness.
01:47Okay, so let me show you on this board.
01:48You can see that it's kind of cupped and I'm going to use this cupped side as the face that I want facing out on the door
01:54that's going to preserve as much character as possible.
01:56And so I'm slowly going to pass it over the jointer and it's going to take down these two sides
02:00until the point where I have a uniform flatness on these two sides
02:06so that when I go to flip it over under the planer and plane this backside off to thickness,
02:10I know that I'm going to get a straight board.
02:12So we're dealing with crooked, weird, twisted boards and we're trying to get one side flat
02:17and off that flat side we'll build 90s and uniform thickness so that when we go to assemble our door
02:22everything fits together good.
02:23But at the same time we're trying to preserve as much character as possible.
02:26So it's finding that balance between nice square flat wood and preserving some of the characters
02:31so that the hallmarks of a barn wood door are present.
02:41Okay, now with three or four or five or whatever passes it was,
02:44now I have, if you look down the board, you can see that it's a flat board
02:47and even though it's lower in the middle, that's not going to mess up my joinery.
02:53So I want to have a nice joint on the two sides here and on the top sides,
02:57which we're going to cut off afterwards.
02:59But I've got a flat surface, meaning when I go and place it down on the planer
03:03and it runs through, it's not running through all screwy so that the blades,
03:07when they come and engage in the top, they're going to take it off in a uniform manner
03:10and I can get a perfect thickness board.
03:12So I'm going to stop right there.
03:14I'm still going to clean this up and sand it.
03:16But essentially what's going to end up happening is this is going to be all the nice character
03:19and then I've got a nice uniform board to work with.
03:22So after this, I'm actually going to join one side so that I know off of this front side,
03:27which is running against my fence, I'm now going to get a 90.
03:30And then from there, I can go to the table saw to cut them to the right thickness
03:34and then plane down there.
03:37And now I've got this board with one flat side and one 90.
03:41And off of that 90, I can rip this side to a uniform width.
03:45And off of this front side, I can plane it down to a uniform thickness.
03:48So I'll do that to all the boards, preserving as much character as I can.
03:51And then we can move on to the joinery steps.
03:53Okay. So I've got the one side all done and the second side squared up.
03:56So now I'm going to flip over my combo planer jointer unit here
04:00and plane them all down to the thickness that I want for the door.
04:03Okay. So I've got them all joined on one side, planed, so they're all the same thickness.
04:16And I've got one side joined in a nice 90 degree.
04:18And now I'm going to get my boards all the same width.
04:21So I'm going to run it through on the table saw and I want these to end up being five inches,
04:25but I'm going to do them just over five inches.
04:27I'll cut them all and then I'll run them through the planer standing vertically.
04:30And then I know I've got them all exactly the same uniform width.
04:42Okay. Now I've just run these off the table saw.
04:43And the reason that I'm now going to run them through the planer,
04:45as you can see that even though the table saw was set straight and I ran it through as good as I could,
04:49there's still like little variations in the board and the board might've just bent a little bit or twisted a little bit as it was going through.
04:56So now I'm going to run them through the planer like this.
04:58So it takes them all down nice and perfect and all in reference to the bottom side,
05:04which I've already run through on the jointer, which I know is nice and flat.
05:07Okay. So now all this crooked dirty barn wood is all straight and uniform and square,
05:15and we can move on to the next step.
05:16And what we want to do now is on the insides of these rails and styles,
05:20we're going to mortise out the center so that our panels will fit inside.
05:25Okay. As with a lot of things in woodwork, there's a lot of ways to do a task.
05:29This is one way to mortise out the center of your boards.
05:32You use your router and then there's a jig that I have on the bottom with mortising pins.
05:37And so what happens is you put it on top of your board.
05:40We want to cut out the center.
05:42And in this case, I don't have to do any math, any figuring, any calculations.
05:45You twist it until the two pins are snug against the board,
05:50and then you can plunge down and pull through and it finds the center for you,
05:54as long as you've set your base on so that your bit is in the center.
05:57And so I've gone and set, I want this to go down,
06:00this mortise is going to go down three quarters of an inch,
06:02and I've got a three quarter inch bit inside of there.
06:05And so I've set on the side of my router this depth stop that goes against the screw.
06:10It maxes out at three quarters of an inch.
06:12So I'm going to put the router on top, twist it until it finds the center,
06:16start to plunge in what I consider to be a reasonable amount,
06:19and then I'll go through the whole board,
06:21and then I'll just keep going over back and forth until I get to the very bottom.
06:25And I can go through all my boards like that.
06:27Now, usually on these boards, I leave them all really long,
06:30because you can tell that I'm not going to be able to reach all the way into.
06:33My first pin has to engage right there.
06:35If I'm not on, then it won't center.
06:37And so you don't make it all the way to either end.
06:40So usually I leave my boards longer,
06:42and then that way I can router and mortise right through.
06:44But in this case, the boards weren't quite long enough.
06:46And so I'm going to end up with a little lip inside here that I'll have to clean out with a saw and a chisel afterwards,
06:51which is fine.
06:52And now you can see here, I've mortised out that center and it makes really nice square edges.
07:10It's nice and square and uniform and centered all the way along there.
07:17I'll have to cut out this little piece at the end here.
07:20Okay, so the rails and stiles are all joined and plain and cut and they're ready to go.
07:29They've got the mortises in them so that the side pieces are mortised all the way through.
07:33And then these are the top, bottom and middle pieces.
07:36And the top and bottoms only have one side with it mortised out.
07:41And the middle ones have both sides mortised out.
07:45And that way when the panels go in, they obviously fit in the top and the bottom.
07:48Now I don't clean out these because I'm going to cut these out and make the long tenons that pass all the way through.
07:54So this is getting cut out anyways.
07:55But now I'm going to stop doing this for a second.
07:58And I'm going to join and plain and glue up the panels that will go on the inside of these doors and let them set overnight.
08:05And then tomorrow when I come and assemble all this, they'll be ready to go.
08:18Okay, so now we've got all these boards joined and planes and square on the edges and we can go and glue them up.
08:26And this will be the four panels that are going inside the two doors.
08:30And I've done the best that I can to get level boards or uniform thickness boards and leave some of the character on what will end up being the front side of the door.
08:39So we've got kind of maximum character.
08:41Okay, now it's glue up time.
08:44And I'm going to set these boards in here and do a quick test clamp.
08:49And then we'll glue.
08:50I think everything's okay, but it's always a good idea to do a little quick test.
08:55I've got a nice flat surface.
09:00All my joints look nice and tight and closed.
09:04So we'll go ahead and throw some glue on this.
09:08And then I've got three more of them to do.
09:10I'm going to let them sit overnight and they can go in the doors in the morning.
09:17Okay, so it's tomorrow now and these are all dried and ready to go.
09:20So I'm going to unclamp everything.
09:22I cleaned the glue off the top last night before I left.
09:24I'll clean the bottom off and then we'll run them through the dual drum sander to smooth them all out.
09:29I actually left them all just a tiny bit high.
09:32Like I wanted them at three quarters of an inch and I left them just a hair above that.
09:36So that if there was any irregularities or they moved a tiny bit, when I now go and pass them through the drum sander,
09:43I can level them all out just to the thickness that I want so they fit in the mortises that I made for the doors.
09:48Now before I run these through the drum sander, I'm going to clean them all up.
09:56You see that I did the skip planing, but a lot of this is still kind of dirty and stuff like that.
10:00And so I'm going to use an 80 grit sandpaper just to lightly go over everything.
10:05I clean up all the saw marks and any leftover glue so that I've got a smooth task when I start putting them through the drum sander.
10:19Okay, now this is my big angry dual drum sander.
10:21It's big, it's green, and it's mean.
10:24Basically, it's got two rollers inside there.
10:27And don't do this because it's dangerous, but I'm going to show you.
10:35Those two babies spin.
10:36I've got the back one set just a tiny bit lower than the front one.
10:39So they both just take off a tiny little bit.
10:42I'm going to run these through on the backside.
10:44I'm happy with the tops.
10:45I'm going to flip them over and then plane them down or sand them down to thickness on the backside.
10:50Okay, so now we're going to quickly double check that the size of my panels fits inside these slots that I made.
11:12There we go.
11:13That fits good.
11:14So we're done with those and we can now trim these up to the right size.
11:17Okay, so now it's time to trim these all down.
11:19It's almost the right width and then I have to trim the top down.
11:22So I've got my fence set here on my slide saw.
11:25It runs perpendicular to my blade.
11:26I'm going to square one side up and then off of that side,
11:29I've got my two stopper set for the height and the width and I can trim these all up.
11:35Okay, so I've got this all nice and square now.
11:45I'll do the rest of them and then we can move on to some joinery on the stiles and rails.
11:50Okay, so with our rails and stiles all done, we now want to work on the joinery which is going to be the haunched tenon pass-through tenons.
11:57So our stiles I'm going to have to take to the chisel mortiser and I'm going to chisel mortis all the way through so the tenons will pass through.
12:05And on these rails I've got to make the tenons and on the top and bottom the little haunched piece that slides inside the mortise that prevents them from twisting a little bit.
12:14And there's a lot of ways to do that.
12:16I'm going to show you a way with setting the depth on your slide miter saw and then using a router to clean them out to get nice predictable tenons and then we can move to assembly.
12:26Okay, and again, there's a lot of ways to do this. This is one way of doing it.
12:29So I've already gone and marked out where the shoulder of the rail is going to be meeting up with the stile.
12:35And so now I need to cut this out and I know that I need to cut this amount out up until the edge of that mortise.
12:40And so on the side of my saw, I've got a depth gauge that I can set and then it goes down and will stop it.
12:47And so I've set the depth so that my saw goes down and won't go any further than just above the place where I want to cut out.
12:55So all I'm going to do is line up my line. I'm going to cut it through and pass through.
12:59And you have to have this board here in the back or else you don't get a straight cut all the way through.
13:03By the time you get to the backside of it, you end up with a little bit of a lip.
13:07So this way you get a flat pass all the way through.
13:10After I've cut that, I know that's my shoulder.
13:12And then I'm going to take it over to the router setup to clean out all the rest of it.
13:20Okay, so this is a pretty simple setup here.
13:22I've got one of the boards that's the same height as the boards I'm trying to work with.
13:26And I'm going to come and set it up against the side of it.
13:30I'm going to clamp it down.
13:31And then on the bottom of my big router here, I have a giant piece of plexiglass.
13:35And what that allows me to do is I have more of a more of a base and I can pass over and I can govern the depth of my router.
13:44And so I've got one wing on this side and obviously the board on this side and that holds up this piece of plexiglass.
13:50And so wherever I set the depth of my router, that allows me to get a uniform cut across the whole thing.
13:56So I'll do it in it in two or three passes, the very last pass kind of being the easiest one.
14:01And then I can clean out the whole top side of that tenon.
14:03I'll flip it over and do the bottom side.
14:06And then with just a router and a saw, I've got my tenons ready.
14:16We'll be sneaking our way down until we get just to that line right there.
14:20Okay, now we've just got this last little bit that I'll clean off.
14:31Okay, now we'll flip this one over and cut off either side of the tenon.
14:40Now I still have to cut off these two top pieces here for the tenon, but we're just going to check and make sure that it fits right.
14:48Because that's where it's sliding in. So I know my depth is set right.
14:51And I can go ahead and make all these now.
14:54And then we'll cut off these ends and make the haunch tenons on the upper and lower rails.
15:06Okay, now we're making the haunch tenon side right here.
15:08This side's already cut off where the panel is going to fit inside.
15:11And then I've got a little three-quarter by three-quarter notch that has to sit on this side.
15:15So I've gone and ripped down as far as I can on this other side.
15:19Now I set my blade up three-quarters of an inch and I set my distance to the fence.
15:25And I'm going to cut it off and then I'll finish trimming it with the saw and then it fits in like a charm.
15:29And now to test it, just to make sure I've got it the right depth, I'm going to set it in this side here.
15:43And then just make sure that my joint goes tight and it's hitting into the bottom.
15:47So we're good.
15:49Okay, with these all cut, now the last thing is these are, as I mentioned, pass-through.
15:54So they're going to sit and pass in through here.
15:56So I'm going to mark out where the full pass-through mortises have to go and then use the mortise chisel to chisel that out.
16:04So this one has nothing on it except the tenon.
16:08And then this one has this haunch tenon here on the end which fits inside that slot and holds these boards nice and straight.
16:15Okay, so now this is one of the funnest machines to use.
16:17This is called a chisel mortise or a mortiser.
16:20And it's all set up so that you clamp your board in and with these dials you can move back and forth without having to unclamp and move your board.
16:27And inside this chisel mortise is basically a drill bit and then this square chisel.
16:34And because I've done everything with a three-quarter inch bit up till now and this is a three-quarter inch chisel mortise,
16:40it's going to fit just right down in that slot.
16:42So I'm going to be able to go through and chisel out the exact width of all the boards that I've already cut and for the mortise that I've already cut.
16:50So what I'm going to do is set this in here and you'll see that I'll clamp it down and then I can move back and forth and I'll go and chisel through about halfway.
16:59Then I'll flip the board over and chisel out the bottom side so that they're full pass-through.
17:03Some guys won't do the full pass-through, I just kind of like how it looks on the backside when you do it.
17:07You could just go out to a certain depth, set your depth stop and then go like three-quarters the way for example,
17:12then leave it so you don't see the end grain on the outside of the door.
17:16I just like seeing it, so I do it.
17:18There, now you can do it.
17:19I'm going to do it.
17:20I'm going to do it.
17:25There, now you can see that it's hollowed out.
17:38I've got to go clean it out with a chisel there a little bit but now we've got the full pass-through at the depth of three-quarters of an inch.
17:56Okay, so the pieces are all ready.
17:57We're going to do a quick test fit to make sure it all fits and then we can assemble.
18:06Okay, quick review.
18:07You can see this honched tenon right there is sitting right where it's supposed to and the joints are nice and tight.
18:12We've got it all mortised out and they're all lining up real nice for our panels to fit in.
18:18And I left these sitting out.
18:20They kind of, they fought with a little bit of junk but I left them both sitting out proud so that I could sand them off afterwards.
18:28But yeah, pretty happy.
18:30We'll keep that.
18:31Okay, so now with all the pieces ready, we're going to assemble.
18:34I've got some type-on glue.
18:35I'll put it in all the joints.
18:36I'll put the three rails into the style that's closest to you.
18:39Then I'll slide my two panels in and then I'll put the top style on and then clamp it all together.
19:00Okay, so the doors are all glued and out of their clamps and now I'm going to go over the whole thing and do a clean up sand.
19:06So a lot of these areas I haven't cleaned up at all and you can see they're still kind of weathered and whatnot.
19:11So I'm going to go over it and sand it just until it reveals a bunch of the character but still gives me a flat surface to work off of.
19:18Then we've got to trim all of these pass-through tenons.
19:21So I'm going to use the jigsaw and the sander to trim those flat.
19:24And then I'm going to go and put in some studs.
19:27Okay, now when we made these tenons, we made them long and they're sticking outside of these styles.
19:36So I'm going to come and trim them with the jigsaw and then sand them down flat.
19:39Okay, now with these barn doors, there's a slot, there's a little floor guide that goes on the floor that stops your door from swinging out.
19:52And there's a number of ways to cut the slot in the bottom.
19:55One of the quickest ways I've found is actually use a biscuit jointer.
19:58So I'm going to go find the center with this centering scribe right here.
20:02I'll put my pencil inside, twist it, which makes it find the center.
20:05I'll make a line and then the blade on my biscuit jointer is just as wide as this guide.
20:13So to give it a little bit of room so it's not just rubbing on there tight, I'm going to go a little bit above and a little bit below.
20:18So I'll do it in two passes.
20:20And then when I go mount this on the floor, it'll slide on nice and easy.
20:24Okay, and then right here on the side of your biscuit jointer, that red line is the center line.
20:31So I'm going to come and I'll loosen it off and then I can just set to where it's the center.
20:36Now I'm going to do one cut that's a little bit above and one cut that's a little bit below.
20:41And then that way I've given myself enough room for the guide to slide on nice and easy.
20:54There, now you've got that nice slot in the bottom that that little guide can run along.
21:00Okay, and with that all done, now we're going to put in some of these hammered steel studs.
21:05So they've just got a little nail on the bottom.
21:07I've gone and marked out the center on all of my rails.
21:10I'm just going to go and do a little pre-drill and then hit him in with a rubber mallet.
21:14And they just, they're just kind of a nice steel accent for this old barn wood.
21:27I still have to put the track wheels on.
21:29So the kit becomes the little guide.
21:31So you just center it, put in your style, make your first mark.
21:34They want you to make two, but basically I make my first mark and then I bolt it in.
21:39And then I make my second mark using this deal itself.
21:42So I'll just push to the side, make the second hole, and then I can bolt it in.
21:46I'll clamp a board underneath so that I don't get much blowout on the bottom.
21:51I'm going to use this Miles Craft jig here to give me a nice straight up and down drill hole all the way through.
22:09Okay, that's a wrap on these doors.
22:20I'm still going to put the floor guides on and the little deals up top.
22:23I hope you enjoyed it.
22:24If you want to see a video about making council joints, click here.
22:27If you want to follow me, click here.
22:28And if you want to see a video about making barn doors with the plywood and barn wood veneer method, click over here.
22:39please.
22:40Thank you, individu!
22:42Thank you guys for joining us!
22:44Let me ring this on this.
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