Milo Valley Farm - barn doors, part 3

by brae  

Continuing work on the barn doors.  I cut new upper reinforcements from basswood since I didn't like the texture of the plywood edges.  I marred the basswood pieces to make them look like old wood.

I added all the nail detailing I needed to finish the overall look and then installed the pieces.

As noted before, I will be making a rail that will extend past the end of the building on either side.  I saw this setup in real life at a wedding locale -- Proven Ground Farm.

The real life version has a round metal pipe that houses the top part of the hardware attached to the barn.  My best guess is there are rollers inside the pipe.

I'm using rectangular plastic tubing to have a larger surface to attach to the barn itself.  The first order of business was to cut a track opening.  I sandwiched the tube between two boards and taped everything together.  I clamped the boards to my cutting table.

Using a sharp X-Acto blade and a metal ruler, I made a tiny channel in the tube.

I left the tube long so I would have enough leverage to hold onto it.  After the channels were in place, I cut the tubes to fit.  Each tube has a channel that is closed on one end and open on the other.

Bill sent me some zinc metal sheet awhile back.  He likes working with it to make interesting minis.  I haven't worked with metal a lot, but this is a fine time to start!  I cut four strips 5/16" wide by 2" long.  I wanted some extra length since I was making things up on the fly.

I bent the zinc over the tops of the barn doors, two per door.  I marked and cut the excess, using nail clippers to smooth the corners.

I marked the brackets for tiny brads on each side.  The nails are on order and I have to paint the hardware anyway, so the slight delay won't be for too long. I drilled a hole in each top center.  This will hold a ball-top sewing pin, cut to fit.

These will serve as the rollers inside the tubing.

Next up, painting the plastic, hardware and installing the doors...

11 comments

Comment from: Debora [Visitor]
Love it! It's ingenious!
02/06/16 @ 16:10
Comment from: azteclady [Visitor]
I am always absolutely amazed at how you come up with alternative solutions to these practical questions--such as choosing rectangular plastic tubing instead of round for your rails, since it will provide more gluing surface. These are not questions that would have occurred to the people coming up with the real life size door, but that are crucial in miniature.
02/06/16 @ 17:27
Comment from: Bill [Visitor]
My workshop has an 8 foot high, 12 foot wide sliding door that has commercially-made square tubing track, so your's is not just stronger to glue than round tubing, it is also authentic for at least one manufacturer. I think using the pins for the rollers is brilliant, and they probably move a lot smoother than the wheels on my door. Glad to see the zinc put to such good use, too. Great work as usual!
02/06/16 @ 17:50
Comment from: BunnyD [Visitor]
Brilliant! Love your set up to make the rolling barn doors workable. The zinc looks like a great malleable material to work with.
02/06/16 @ 18:01
Comment from: Blondie [Visitor]
Bravo!! That looks great! :)
02/06/16 @ 20:03
Comment from: Monique [Visitor]
that is so smart with the pins and tubeand it looks so great already! I like it that the doors slide open besides the building, like that RL-location, it adds something somehow that I find to add interest to it.
02/07/16 @ 04:05
Comment from: Mad for Mod [Visitor]
Awesome!
02/07/16 @ 10:33
Comment from: Betsy Rogers [Visitor]
We had an extended door roller track exactly like that on our barn! Ours extended far enough to warrant a support post at the outer end. (Also prevented heavy machinery from "taking it out" by accident!) I always love seeing your ingenuity in action!!! Round pin heads for "rollers"!!! Bravo!
02/08/16 @ 16:54
Comment from: brae [Member]
:>> Thank you!!!
02/09/16 @ 10:04
Comment from: Lyssa [Visitor]
You, my pea pod friend, are a ridiculously amazing mcgyvering GENIUS! That is the coolest mini I have seen. Ever.
02/09/16 @ 13:20
Comment from: brae [Member]
:)) Thanks, Pea!
02/09/16 @ 13:29


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