Project Details

In the world of custom carpentry and design, every project presents its own set of challenges and creative opportunities. Recently, I had the privilege of working on a truly exceptional project that demanded not only precision and craftsmanship but also a touch of artistic flair. The task at hand was to fill an unconventional opening for a room without a traditional door. Measuring at 38 3/8” by 95”, this unique space called for something extraordinary. To make it even more special, my client had a specific request: a sunbeam pattern on the door.

The Creative Vision

The client’s vision was clear – they wanted to bring the warmth and radiance of the sun into their living space. To achieve this, I set out to craft a 40”x97” hanging door that would not only fulfill its functional purpose but also serve as a work of art in its own right. Constructed from durable melamine, this door would not only be aesthetically pleasing but also easy to clean and maintain.

The sunbeam pattern, the heart of the project, required meticulous attention to detail. To create the raised sunbeam design on both sides of the door, I turned to MDF (Medium Density Fiberboard), a versatile material known for its smooth surface and ease of customization. Carving the intricate sunbeam pattern was a labor of love, requiring precision and patience.

Delivery and Installation

Once the door was completed, it was time to prepare it for installation. Weighing in at 75 pounds, this door was a substantial piece. To ensure its integrity during transportation, I wrapped it in protective bubble wrap for its journey to the client’s home. Upon arrival, I carefully unwrapped the door, revealing its elegant design.

Delivering the door

Unwrapping it

The installation process involved more than just hanging the door. I attached a robust 7’ header made from hard maple to the room’s entrance. Using ten heavy-duty drywall anchors securely fastened into the client’s steel studs, I ensured that the door would be not only beautiful but also safe and reliable.

Positioning the header

Drilling holes for the anchors

Screwing in the anchors

To facilitate smooth and silent operation, I added heavy duty barn door hardware to the header and attached wheels to the door itself. The result was a stunning sunbeam barn door that effortlessly glided open and closed, serving as both a functional barrier and a captivating focal point in the room.

Installing the barn door rail

Attaching the wheels

Complete

This project was a testament to the power of craftsmanship and creativity. It showcased how a seemingly awkward space could be transformed into something truly exceptional with the right vision and skills. If you have a unique project in mind, whether it’s a custom door like this one or another creative endeavor, don’t hesitate to reach out. I’m here to bring your ideas to life and create functional art that enhances your living spaces.

Finished