Attach the Caster Boxes

Position one large caster box (pocket-hole end) centered on the short box side of one small caster box and attach using glue and 1-1/4-inch pocket-hole screws as shown here. Repeat to create a second assembly, which will be referred to as an end caster assembly.

Position the small caster box assembly without box ends centered on the short box side of two small caster boxes and attach using glue and 1-1/4-inch pocket-hole screws. This is now the center caster assembly.

Attach the Casters

On the inside of the end caster assemblies, position a 2-inch swivel caster at each end of the small caster box and the end of the large caster box near the box end so the caster rotates 360 degrees without touching an edge (shown here). You should use three casters total for each end caster assembly. Attach using 1/2-inch washer-head screws.

On the inside of the center caster assembly, position a 2-inch swivel caster at each end of the small caster boxes so the caster rotates 360 degrees without touching an edge. You should use four casters total. Attach using 1/2-inch washer-head screws.

Prepare the Doors

Paint the doors, except for the panels, a semigloss white. Allow to dry. Use painter's tape to tape off each panel of the doors. Paint the panels your desired color.

Attach the Caster Boxes to Doors

Mark a center line on the edge of each door at the bottom. Mark a center line on the end of the large caster box and on the short box sides of the end caster assemblies.

Mark a center line on the end of the short box sides (positioned on the end) of the center caster assembly. Attach the center caster assembly centered on the bottom of one door using seven 2-1/2-inch wood screws.

Position the end caster assemblies centered and flush with one end of the doors and attach using seven 2-1/2-inch wood screws.

Put Everything Together

Place the three door assemblies in the desired room. Position the doors with the end caster assemblies on each side of the door with the center caster assembly. Make sure the short box sides of the end caster assemblies are positioned on the ends.

On the end doors, attach one side of two 3-inch surface mounted bi-fold hinges, one positioned six inches from the top of the door and one positioned six inches from the bottom.

Attach the other side of the hinges to the middle door.

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