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Z Barn Door Installation Instructions

The Z Barn is one of the iconic Barn Doors that is timeless, and will make almost any space better. PDF instructions for the Z Barn Door are also available.

Z Barn Door Instructions & Video

Z Barn Door Recommended Tools
  • Drill with Phillips Bit
  • Socket Wrench with 7/16" Socket
  • Rubber Mallet
  • Adjustable Square

Z Barn Door Parts
  • Side Stile Left (1)
  • Side Stile Right (1)
  • Bottom Rail (1)
  • Diagonal Overlay (2)
  • Left Side Slat (1)
  • Middle Slats (6*)
  • Right Side Slat (1)
  • 3/4" Phillips Screws (30*)
  • 6" Lag Screws (6*)

Z Barn Door Assembly Instructions & Video

First Things First

Lay out all wood parts before beginning assembly to ensure parts have not been damaged in shipping. damage has occurred, call 800-891-8312 and Rustica Hardware will expedite a replacement.

Note: This door model comes in various sizes. The instructions have been written for the single door size; but larger doors may have more wood and fastener parts.

Note: Always alternate the direction of the wood grain when assembling slats. This will add to the assembly and help prevent warpage.

Note: Doors using Floor Mount Door Guides have a groove on the bottom edge. Ensure this groove is on the bottom when the door.

Z Barn Door Assembly Instructions

By Definition: Tongue and Groove refers to the ridge extending beyond the main portion of slat or stile. Groove refers to the slot cut into the other side of slat or stile.

Note: The following should be a ‘dry’ assembly. Do use adhesives in when putting this door

Step 1: On a flat, clean surface, lay out the right slat (B3) with the groove facing to the left. Lay all middle slats (B2) next to B3 with the tongue facing to the left. Lay the left slat (B1) to the left of the last B2 slat with the groove facing right. Assemble by fitting the tongue into the groove of each piece. Gently tap into place with a rubber mallet to seat the slats together (Figure 1).

z barn door install step 1

Suggestion: Use an adjustable or fixed carpenter’s square to ensure all sides of the door are square to each

z barn door install step 2

Step 2: Place the bottom rail (A2) below the assembled slats. Slide upward to cover the lower edge of the slat assembly. Tap the bottom rail into place with a rubber mallet (Figure 2).

z barn door install step 3

Step 3: Place the Top Rail (A3) above the assembled slats. Slide downward to cover the upper edge of the slat assembly. Tap the Top Rail into place with a rubber mallet (Figure 3).

z barn door install step 4

Step 4: Place the left side style (A1 L) beside the assembled slats and rails. Slide to the right to cover the top and bottom rail tongues and the edge of the slat assembly. Tap the rails into place with a rubber mallet. Repeat with the right stile (A1 R) (Figure 4).

z barn door install step 5

Step 5: Fix the door assembly with six 6” lag screws (E), using a socket wrench with a 7/16” socket (Figure 5).

z barn door install step 6

Step 6: Lay the Diagonal Overlay (C) across the slats. Attach to slats and with phillips screws (D) using a drill with a phillips bit (Figure 6).

Step 7: Turn the door over. Repeat step six for the other side.

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