Step 1: Channel the first board in the center of the length (24”), 5/16” wide cut that straddles the centerline by 1 ft deep.
Step 2: Test channel along the entire 1 ft length by sliding another MDF board through the slit.
Step 3: Widen the channel from the bottom of board 1 to 1 inch in width up to 1 ¼ inch from the edge.
Step 4: The 1” channel meets the 5/16” portion of the channel and creates a 90 degree angle. File this point until it makes a 45 degree angle.
Step 5: Repeat steps 1-4 for board 2.
Step 6: In board 1 make 2 rectangular notches, 3 inches from either side, 2 ½” long, and ½” deep. Note: Notches should be on the opposite side of the board in reference to the channel.
Step 7: In board 2 make 2 rectangular notches, 3 inches from either side, 2 ½” long and ½” deep. Note: Notches should be on the same side of the board in reference to the channel.
Step 8: Sand both sides of the MDF to create a surface ready for paint.
Step 9: Tape out 1” on all external edges on both sides of the MDF with painters tape.
Step 10: Apply the first coat of chalkboard paint on one side of both boards. Allow 4 hours to dry.
Step 11: Apply second (final) coat of chalkboard paint on the same side of both boards. Allow 4 hours to dry.
Step 12: Repeat steps 10-11 for opposite sides of the MDF.
Step 13: On the bottom of each foot, cut a 11/32” channel, 1 ½” deep on the centerline.
Step 14: Cut 4 pieces of trim to 49” in length.
Step 15: Cut each of the 49” pieces on the ends at a 45 degree angle. The top length remains 49” and the bottom should now be 46 ½”.
Step 16: Pick two of the trim pieces from step 15, line up the ends at the top of board 1, with board 1 sitting on top of the trim. This will reveal where the wood piece needs to be cut to separate with the channel created in step 3. Cut the first piece of trim, and repeat all of step 16 with the second piece of trim.
Step 17: Cut 8 pieces of trim for the sides to 24 inches long. Then, create 45 degree angles on both ends with the inside length being 21 ½”.
Step 18: Cut 8 pieces of trim to 3 ½” in length, cut a 45 degree angle on one side of each length.
Step 19: Cut one piece of trim from step 18 to match the inside arc of the foot when fitted to the MDF. Note: the end cut for this step should be opposite end of the piece as the 45 degree cut.
Step 20: Repeat step 19, 7 more times to complete the bottom corner cuts.
Step 21: Cut 4 pieces of trim to 39” in length.
Step 22: Cut each piece of trim from step 21 on both ends to match the inside arc of the feet when fitted to the MDF.
Step 23: Pick two of the pieces from step 22 and line up the ends to the inside arcs of the feet on board 2. This will reveal where the wood piece needs to be cut to fit around the channel in the center created in step 3-5. Mark and cut both piece of trim.
Step 23: With all of the trim pieces completed, fit them around both boards #1 and #2. Mark the backs of each piece with a corresponding letter or number that matches the board. These marks will show which sides need to be kept free from stain and also where the trim needs to be attached to the MDF sheets after they are stained.
Step 24: Stain trim and feet. Note: do not stain the inside channels of the feet.
Step 25: While stain is drying, remove painter’s tape from both boards.
Step 26: Let stained wood sit for 5-10 minutes and then wipe the excess stain off with a rag.
Step 27: When stain is completely dry, use wood glue to glue the feet in the notches cut in the bottoms of boards 1 and 2. The channels cut into the feet should match these notches on the boards. Note: slide the boards together and allow the structure to stand upright and level while drying.
Step 28: When trim and glue on feet have dried, match the letters or numbers to the corresponding locations on boards 1 and 2. Glue the trim into place with wood glue and wipe free of excess.
Step 29: Use ratcheting clamps that are designed for wood to hold pieces in place while they dry. They will take about 4 hours to set completely.
Step 30: After the trim is completely dry, sand all external edges until they are even if necessary. This can be done with a belt sander.
Step 31: Round all of the external 90 degree angles to a smooth edge to ensure safety. This can be done using a sanding block with medium grit paper.
Step 32: Smooth all edges with fine-grit paper, giving the product a soft to the touch feel.
Step 33: Re-stain all of the newly rounded edges and touch up any places on the MDF board that may need paint due to chipping or scratching.
Step 34: Cut and attach Shurtape™ to bottom of the feet to prevent slippage when placing the table on a smooth surface.
Step 35: Condition all surfaces that have been painted with the chalkboard paint. (Per the paint can’s instructions: for the paint listed, cover the surface with chalk and erase to create an even base layer).
Step 36: Enjoy the Chalkboard Tabletop Divider.