How to make a reclaimed wood barn door headboard with faux hardware

FarmhouLearn how to make this cheater reclaimed wood barn door headboard with faux hardware, with a Bed & Breakfast DIY pillow, made with Funky Junk's Old Sign Stencils!
How to make a reclaimed wood barn door headboard with faux hardware

I  still remember the words from those around me when I went to gather up some barn wood lately from a local barn that was coming down. 

View how we scavenged the barn wood in this post HERE

“What will you do with the wood?”

“I have NO idea! But you can bet if it’s sitting in my way, I’ll think of something…”

And it’s true. Ya gotta stock it in order to create with it.

So here’s how to make a reclaimed wood barn door headboard with faux hardware…

(this post contains some affiliate links)

How to wash and protect chippy barn wood, part of a Barn Door Tutorial on funkyjunkinteriors.net

How to prep barnwood

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Read the barn wood shopping story HERE.

So, after I got the wood home, the nails were first removed.

How to wash and protect chippy barn wood, part of a Barn Door Tutorial on funkyjunkinteriors.net
Next up, a good clean right away before storing makes it just that much more fun to use when the time comes.

Generally, the first thing I grab for cleaning reclaimed wood is the pressure washer.

But this paint was weird. If you touched it, it came right off. It was as if it was powder!

Knowing that, I gently hosed both sides off JUST to knock of any cobwebs or dirt.

How to wash and protect chippy barn wood, part of a Barn Door Tutorial on funkyjunkinteriors.net
Then the wood was leaned against the back of the house to air dry.

And then it rained. And rained. And rained again. Good grief.

How to wash and protect chippy barn wood, part of a Barn Door Tutorial on funkyjunkinteriors.net
I was about to bring it under my covered deck when the sun came out! Yes! But that’s when I noted how gorgeous the tones were while wet.

Right then, I KNEW what it had to become.

The old horse gate headboard was about to be retired. Cuz I was gonna build me a faux barn door headboard!

Out of barn wood.

With no barn door hardware.

Yes. I do enjoy a good, self-inflicted challenge…


How to seal and protect chippy barn wood, using Fusion Mineral Paint's Tough Coat, part of a Barn Door Tutorial on funkyjunkinteriors.net
How to seal and protect chippy barn wood, using Fusion Mineral Paint's Tough Coat, part of a Barn Door Tutorial on funkyjunkinteriors.net

How To Protect Chippy Paint On Wood
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.Above left – untreated / above right – treated

Fusion Mineral Paint’s Tough Coat – website link

1. Ensure wood is completely dry, then lightly sand.

2. Apply Tough Coat with a brush following the wood grain.

3. Allow to dry, then lightly sand on a low speed.

(this is why I love a variable speed palm sander) – Amazon affiliate link
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Generally, I rarely protect reclaimed wood. But being that this was painted and was flaking off and located in a bedroom, I wanted to play it extra safe and coat the wood to cover any possible toxic leaks.

So I pulled out Fusion Mineral Paint’s Tough Coat.

Not being completely sure of how it would turn out, I tested a small area first. And goodness… I fell in LOVE!



How to protect chippy barn wood, using Fusion Mineral Paint's Tough Coat, part of a Barn Door Tutorial on funkyjunkinteriors.net
The Tough Coat not only appeared to hydrate the wood, it coated the chipped paint with a level of a matte – satin finish protection that was perfection!

It was like working with an entirely different piece of wood. It drew out the warmth of the wood beautifully and naturally, not adding any added colour.

Bonus – Fusion Mineral Paint’s products don’t smell. They are environmentally friendly. This stuff had a nice faint candy like odour. And I can’t say that for any other stinky clear coat product I’ve used in the past!

How to seal and protect chippy barn wood, using Fusion Mineral Paint's Tough Coat, part of a Barn Door Tutorial on funkyjunkinteriors.net
Once the clear coat was dry (to the touch within minutes!) a light sanding was done to make the wood smooth to the touch.

I used my Bosch variable speed sander, turned down to about #2.

enhancing rust with MMSMP hemp oil

Creating Faux Barn Door Hardware

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casters – 2

large hinges – 2

rusty junk things – 2

Miss Mustard Seed’s Hemp Oil – website link

1. Enhance rust with a coat of hemp oil, applied with a small artist’s paint brush. Wipe off the surplus, and allow to air cure.

Next up was trying to figure out how to make faux barn door hanging hardware.

Looking at some pictures on the net for reference, I came up with 2 antique coasters, 2 metal… things, and 2 hinges.


enhancing rust with MMSMP hemp oil-001
First I used a coat of Miss Mustard Seed’s Hemp Oil to change the hardware from orange to a rich rust. Gorgeous! A little paint brush did the trick.

It worked so well!

HERE is a previous good read on how to protect metal.

barnwood door headboard from reclaimed wood-016

barnwood door headboard from reclaimed wood

Installing the faux barn door

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1. Cut slats of wood the width of your bed, and install to your wall, attaching to wall studs if desired.

For added stability, the slats were installed closer together where I knew I would lean against them. Make sure you run one near the floor moulding as well.

2. Cut barn wood to desired length, then screw the boards into place, one at a time. Ensure you leave enough room for the added hardware to come on top.

The boards are sitting about 1″ off the floor so they can be swept under.

3. Run a strip of wood along the top of the barn door if desired, to trim it out evenly.

4. Mount the faux barn door hardware as shown below.

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A cheater reclaimed wood barn door headboard with faux hardware. Get the look without the expense or difficulty using rusty junk for hardware! funkyjunkinteriors.net
Hanging the junk hardware
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1. A 2×4 was coated out in black, to create the faux rail.

2. The two metal hook things were installed, then the 2×4 slipped in.

3. The caster was placed on top of the 2×4, then threaded through the hinge. Two screws hold the post intact.

4. The hinge was then screwed onto the barn door. 

A cheater reclaimed wood barn door headboard with faux hardware. Get the look without the expense or difficulty using rusty junk for hardware! funkyjunkinteriors.net
How great is that cheat?! And this is why one needs to visit rusty junk bins to collect this stuff!

A cheater reclaimed wood barn door headboard with faux hardware. Get the look without the expense or difficulty using rusty junk for hardware! funkyjunkinteriors.net

Rusty hardware was added to resemble the door being authentic.

For extra quirk, 2 handles were used, since the door was pretty big.

Learn how to make this cheater reclaimed wood barn door headboard with faux hardware, with a Bed & Breakfast DIY pillow, made with Funky Junk's Old Sign Stencils!

The reveal
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And a little bit of bed fluffing later, I had me a barn wood barn door headboard!

Isn’t that wood absolutely stunning?!

A cheater reclaimed wood barn door headboard with faux hardware. Get the look without the expense or difficulty using rusty junk for hardware! funkyjunkinteriors.net

Learn how to make this cheater reclaimed wood barn door headboard with faux hardware, with a Bed & Breakfast DIY pillow, made with Funky Junk's Old Sign Stencils!

Learn how to make this cheater reclaimed wood barn door headboard with faux hardware, with a Bed & Breakfast DIY pillow, made with Funky Junk's Old Sign Stencils!

Find Bed & Breakfast stencil HERE

Funky Junk's Old Sign Stencils store logo


Bed & Breakfast pillow

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The pillow was a fun take for the bedroom! Bed & Breakfast was stenciled onto an Ikea pillow case, chiming in perfectly with the black, white and wood colour scheme.

Paint used: Fusion Mineral Paint’s Coal Black – website link

Learn how to stencil on a pillow HERE

Served Daily is from the LUNCH stencil HERE



Farmhouse black and white rustic sign above a window with white curtains and faux plants, made with Funky Junk's Old Sign Stencils | funkyjunkinteriors.net

Find Farmhouse stencil HERE

Remember the Farmhouse Reclaimed Wood Clock project? The sign landed above the window for a dash of farmhouse charm.

Farmhouse black and white rustic sign made with Funky Junk's Old Sign Stencils | funkyjunkinteriors.net

Learn how to make this cheater reclaimed wood barn door headboard with faux hardware, with a Bed & Breakfast DIY pillow, made with Funky Junk's Old Sign Stencils!
The ladder side table stayed, because it just worked!

And I may make a few changes here and there along the way, but for now…


Learn how to make this cheater reclaimed wood barn door headboard with faux hardware, with a Bed & Breakfast DIY pillow, made with Funky Junk's Old Sign Stencils!

I can’t wait to get deep into a farmhouse styled sleep tonight!

Read the barn wood shopping story HERE.

How I made a matching Antique mirror HERE




Funky Junk's Old Sign StencilsVisit All Stencil ProjectsShop The Store
Disclosure: I work with Fusion Mineral Paint to showcase projects using it and because I love the stuff. I was not monetarily compensated for this post. The stencils are from my own line.

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Categories: All Cool Projects, DIY, Full Rooms, Furniture, Junk Drawer, Old Sign Stencils, Reclaimed wood projects, Signs
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  1. My goodness!!!! We’re you just beaming from ear to ear when you stood back and looked at all of that coolness when you were finished? That is so incredibly unique and gorgeous looking. This has to be one of my most favorite “pins” ever….Can I sleep over? ๐Ÿ˜‰๐Ÿ‘Š๐Ÿผ

  2. Absolutely gorgeous! To look at the photos and the instructions, one can learn to do a barn door for next to nothing or for a fraction of the price. Some of them are so pricey. I enjoyed your detailed how-to and the end project is stunning. Thank you so much for sharing and showing us how something can be done, even when you think you can’t.

  3. I just had to stop by and savor all of the tips in this amazing post. Love the faux barndoor hardware. Simply genius. Susie from The Chelsea Project

  4. Not only do I love this and the ingenuity of the top “barn door hardware,” but I love the one black board interspersed in with the white, that ties with the touch of black elsewhere in the room. A decorator’s eye, for sure.

  5. What a fantastic idea….. some people might have a good point in favor of real over faux flowers but who can argue with a faux barn door that looks this good????? Nobody. That’s who.

  6. you saved a piece of that amazing barn! It’s awesome & I love the black and different hardware! bet it looks cozy at night with just a lamp on

  7. I. love. this. Like you said, not only was it free, and faux, but it’s simply awesome to look at! I agree with Brenda’s comment about the dark board in the middle; sometimes the brain just knows what it needs to do.

    Last week I was making signs with reclaimed boards. I’d painted some of the boards red, before using one of your stencils with white paint. After some light distressing and sanding, the red seemed to fade too much for my liking. I thought, I wonder if just a bit of Miss Mustard Seed furniture wax would make it pop?? Now, that’s what I had on hand, the topcoat you used would be similar … but wow what a little thing that made a huge difference!

  8. That turned out pretty cool. One question, though. Why did you leave the horizontal piece of wood at the top of the door “naked”? It seems like you would have used a piece of aged barn wood to match the vertical boards. All in all, though, the whole thing is really quite awesome. I enjoyed seeing the process.

    • Good eye Naomi! The plank size and flexibility worked in the area. The back side of the board was used as it was more rustic than the smooth finished side, so I decided to roll with it as is. I may have stained it if I had stain that didn’t stink! haha I’ll be ordering some from Fusion so I have all the right things on hand hopefully next round!

  9. Thanks for sharing your faux barndoor headboard!!! I love what you’ve done with your barnwood, and other rusty things. You are such an inspiration!

  10. Wowza Donna, it looks amazing. You just have the touch. I wish someone would figure out how to bottle some of that Donna Junkin essence so I could spritz it around the room and make magic happen

  11. This turned out amazing! And thank you for all of those tips, too! I didn’t know that about MMS’s Hemp Oil enhancing rusty junk, I’m going to have to try that, and the Fusion Tough Coat for the wood, too

  12. This is gorgeous Donna! It makes me want to sell my bedroom set so I can replace it with this! ๐Ÿ™‚

    I’d like to invite you to share this at the brand-new Farmhouse Friday link party which kicks off this Friday at 6:00 am PST! I am giving away a $50 Amazon gift certificate to celebrate, and I will also share your linkup on DIY Farmhouse Style Facebook group where I admin, which at this writing has over 130k members! ๐Ÿ™‚

    Hope to see you on Friday!

    Michelle
    The Painted Hinge
    http://www.thepaintedhinge.com

  13. When I come across one of your posts somewhere online, I always knew itโ€™s your work. Your work is quite unique. I love everything you do!

  14. It’s fantastic, and I love what the Fusion top coat did to make the wood even prettier! Your “faux” barn door hardware totally had me fooled! Just awesome Donna!