I loved the AG Doll House plans you designed and when my granddaughters asked me to make one for them.... how could I resist. Unfortunately my 7' basement ceiling and steps created a challenge. As a 72 year old female, there was no way I could man-handle a 6' x 4' x 2' - 3/4" plywood project in addition to the challenges of my work space. I was not going to disappoint my granddaughters so I had to come up with a plan. Instead of making the doll house in one piece, I decided to make it as 3 individual boxes (the floors) and stack them on top of each other. Not only would I be able to handle them mostly by myself, but I would be able to work around the low ceiling and transport them up the steps. With only a few modifications to the original plans, I believe I came up with a workable solution.
Instead of the sides resting on top of the doll house floor, I extended the sides 3/4" longer to run past the floor for more stability. I also used 1x 2s to frame the inside at the top of each unit for more support and to help in keeping the box square. This may not have been necessary, but I just wanted to make sure it would be sturdy. The main change to the original plan was to add 1" x 3" routed trim to the outside top of each box having it extend 3/4" above the sides. This created a pocket that allowed the next floor to nestle in place and protect it from sliding off in case any little ones decided to climb on it. I also made a 2 car (30" x 30" x 24") detached garage for the AG vehicles. I did fill the holes, plugs, and errors with wood putty, sand numerous times, prime and paint. It was a real help to add some of the paint to the primer because plywood really soaks it up. I think this kept us from having to paint a 3rd coat. The floor was painted a med dark brown, but wiped with the grain before it dried to give a wood grain look.
I finished it in time for the birthday party even though it took 3 vehicles to transport it to the destination. It was a joy to see their faces when it was unveiled and to watch them climb on it of course.