If your holiday houseguests will be sleeping in your living room or family room, they will need some privacy. Construct a room divider that covers the doorway into the room to make things more comfortable for them. Using some hollow-core doors makes the divider lightweight for easy moving and storage.
You will need:
• 1 board measuring 1x3x8 feet
• 1 board measuring 1x3x6 feet
• 3 boards measuring 1x2x6 feet
• #18 x 1 ¼-inch wire brads
• ½-inch washer-head screws
• 2 ½-inch wood screws
• 1 ¼-inch pocket-hole screws (coarse thread)
• 10 swiveling 2-inch casters
• 4 3-inch bi-fold hinges (surface-mounted)
• 3 six-panel, 30-inch slab doors
• Hand saw featuring a miter box or a miter saw
• Wood glue
• Drill with a pocket-hole jig
• Pocket-hole clamp (right-angle)
• Measuring tape
• Semigloss white paint
• Paint color that matches decor
• Painter’s tape
Step 1: Cut 10 pieces of wood to measure ¾ x 2 ½ x16 inches- these will be the short box sides. Cut 5 pieces to measure ¾ x 3 ½ x 16 inches- these will be the short box lids. Cut 10 pieces to measure ¾ x 3 ½ x 1 ¾ inches- these will be the box ends. Cut 4 pieces to measure ¾ x 2 ½ x 23 inches- these will be the long box sides. Cut 2 pieces to measure ¾ x 3 ½ x 23 inches- these will be the long box lids.
Step 2: Assemble the four small caster boxes. Use the 1 ¼-inch brads and the wood glue to fasten all pieces together. Each box features 2 short box sides, 2 box ends, and 1 short box lid.
Step 3: Take each long box side and create 2 pocket holes in one end with the drill. Make sure that one hole is a minimum of 3/4-inch away from an edge.
Step 4: Assemble the two large caster boxes. The sides should be positioned so pocket holes can be seen beyond the lid edge and are located on the opposite end of each box end. Use the brads and glue to fasten all pieces.
Step 5: Create two pocket holes in the ends of short box sides that remain, using the drill and making one hole a minimum of ¾-inch from an edge.
Step 6: Use the brads and glue to attach the two remaining short box sides to your remaining short box lid. The pocket holes on the sides should be visible beyond the lid edge. No box ends will be attached.
Step 7: Center the pocket-hole end of one of the large caster boxes on the short side of a small caster box, Use the pocket-hole screws and glue to attach this. Repeat the process to create another assembly, called the end caster assembly.
Step 8: Center the small box assembly that does not have box ends on the short side of two of the small caster boxes. Use the pocket-hole screws and glue to attach this, creating the center caster assembly.
Step 9: Position casters on the interior of each end caster assembly, locating one at each end of the small caster box. Place a caster at the end of the large box, positioning it so the caster can rotate completely without touching any edges. Three casters should be used for each of the end caster assemblies. Attach these with the washer-head screws.
Step 10: Move to the interior of your center caster assembly and position a swivel caster at each end of the small boxes. Make sure the caster can completely rotate without touching any edges. Four casters should be attached using the washer-head screws.
Step 11: Tape off the door panels. Paint doors with the semigloss white paint, leaving the panels unpainted. Let the paint dry. Paint panels a color that coordinates with the décor.
Step 12: Create a center line at the bottom edge of each door. Create a center line at the end of the large caster box. Create another center line on each end caster assembly, placing it on the short sides.
Step 13: Mark another center line on the center caster assembly at the end of each short side.
Step 14: Center the center caster assembly on the bottom of a door and attach it with the wood screws.
Step 15: Center the end caster assemblies and make sure they are flush with an end of the doors. Attach them with the wood screws.
Step 16: Move the door assemblies into the room where they will be used. Position doors so the end caster assemblies are on each side of the door featuring the center caster assembly. The short box sides should be positioned on the ends.
Step 17: Attach one side of the bi-fold hinges to the end doors. Position one 6 inches from the top and one 6 inches from the bottom.
Step 18: Attach the other hinge side to the middle door.