Introduction

Hollow-core doors are lightweight, so they'll be easy to move and store after your houseguests go home.  The doors are also inexpensive — you can find them for about $25 each. Try a salvage shop for old doors, they'll give your divider a unique personality.

Step 1

Room Divider Cutlist

Cut the Lumber

For the short box sides — cut (10) 3/4" x 2-1/2" x 16" pieces 

For the short box lids — cut (5) 3/4" x 3-1/2" x 16" pieces 

For the box ends — cut (10) 3/4" x 3-1/2" x 1-3/4" pieces 

For the long box sides — cut (4) 3/4" x 2-1/2" x 23" pieces  

For the long box lids — cut (2) 3/4" x 3-1/2" x 23" pieces 

Step 2

Build the Small Caster Boxes

Use the drawing as a guide to assemble four small caster boxes. Fasten the pieces together using glue and 1-1/4" brads. These boxes are comprised of two short box sides, one short box lid and two box ends. Drill two pocket holes on one end of each long box side. Be sure to position one pocket hole at least 3/4" away from one edge.

Step 3

Build the Large Caster Boxes

Use the drawing as a guide to assemble two large caster boxes. Fasten the pieces using glue and 1-1/4" brads. Make sure the long box sides are positioned so the pocket holes are visible beyond the edge of the long box lids and are on the opposite end of the box ends. Drill two pocket holes on each end of the two remaining short box sides. Be sure to position one pocket hole at least 3/4" away from one edge.

Attach these short box sides to the remaining short box lid using glue and 1-1/4" brads. Make sure the pocket holes on the short box sides are visible beyond the edge of the short box lids. No box ends are attached to this assembly.

Step 4

Clamping caster box

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" 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" pocket-hole screws. This is now the center caster assembly.

Step 5

Wheel Casters installed

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" washer-head screws.

On the inside of the center caster assembly, position a 2" 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" washer-head screws.

Step 6

Painting door

Prepare the Doors

Paint the doors, except for the panels with a semi-gloss paint. Allow to dry. Use painter's tape to tape off each panel of the doors. Paint the panels your desired color.

Step 7

Room Divider Construction

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" wood screws. 

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

Step 8

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.