How To Make A Cornhole Set In 2 Days
- Shopsmith
- 5 days ago
- 5 min read
PROJECT TIME | COMPLEXITY | COST |
Two Days | Beginner | About $200 |
INTRO
Cornhole is a great game for people of all ages and it's the perfect outdoor activity for your next backyard get-together. This project is a super fun build and it was also designed for the woodworking beginner in mind. Follow the build instructions below and customize it however you like. The projects includes nets to hold the beanbags, plus you can fold it up for easy carrying. (Overall dimensions: 24-in. W x 48-in. D x 4-1/4-in. H)
Cutting List
KEY | QTY | PART | DIMENSIONS |
A | 2 | Board Top | 24” x 48” x 3/4” |
B | 4 | Skirt Sides | 46” x 3-1/2” x 3/4” |
C | 4 | Skirt Ends | 20-1/2” x 3-1/2” x 3/4” |
D | 4 | Legs | 14” x 3-1/2” x 3/4” |
E | 4 | Cross Braces | 20-1/2” x 2” x 3/4” |
Tools Required
1" forstner bit
3/8-in. round-over router bit
Drill/driver
Jigsaw
Miter saw (optional)
Pocket hole jig
Preval sprayer (optional)
Router
Table saw
Materials Required
1-1/4" pocket screws
2 - 24” x 48” x 3/4" Marine-grade plywood
2 - Pairs of slip hinges
2" washer-head screws
4 - 3/8-in. Threaded knob
4 - 3/8" x 2-1/4" Carriage bolt
8 - 1” x 4” x 8’ Pine boards
Fender washers
Motorcycle cargo netting
Shellac
Spar Varnish
Spirit levels
TransTint wood dye
Project Step-By-Step (16 Easy Steps)
Follow these simple steps to create your custom cornhole set. Watch the video below for more details.
Step 1 - Make The Skirt
Cut the Skirt Boards. Gang-cut the skirt ends (C) and sides (B) from 1×4 select pine boards to ensure they’re the exact same length.
Step 2 - Cut The Handle Slots
Cut a handle slot in two of the skirt sides (B), one for each board. Mark the center lengthwise, then mark a line 1-1/2-in. from the bottom. Measure out 2-1/2-in. from both sides of center and, with a one-inch Forstner bit, drill two holes on those marks. Remove the rest of the waste with a jigsaw.
Step 3 - Round Over The Slots
Round over the handle slot with a 3/8-in.-radius router bit. Round over the outside profile and the inside
Step 4 - Drill Pocket Holes and Assemble The Skirt
Drill pocket holes in the skirt sides (B) and ends (C) every eight inches for fastening the top (A). Drill two pocket holes on the skirt ends (C) to fasten the skirts together. Once you’ve drilled the pocket holes, clamp the skirt sides (B) and ends (C) together while you set the pocket screws. This keeps the parts from shifting as the screws tighten down.
Step 5 - Make The Legs
Trim the Legs. The legs (D) need to be slightly narrower than the skirt boards (B and C) so they sit inside the frame when stowed away. Cut them to 3-1/4-in. wide on the table saw. Once they’ve been cut down, tack or tape the legs together. Mark the cuts for the angled foot, the bolt hole and the half-round shape at the top of the leg.
Step 6 - Cut To Shape
Cut the half-round shape with a band saw or jigsaw while the legs (D) are tacked together. Make the 30-degree angled cut for the foot with any saw you’re comfortable with; we used the band saw. Then drill a 3/8-in. hole for the carriage bolt centered on the width, 1-5/8-in. down from the top.
Step 7 - Finish The Legs And Skirt
Chose a gel stain from your favorite brand for the skirt to accent the bright colors of the cornhole boards. Apply a coat of wood stain to the skirt and the legs. Let them dry for 24 hours, then top with three coats of spar varnish.
Step 8 - Make The Boards
Create a Custom Look. This step is optional, but we wanted to make these cornhole boards unique. Cut the plywood tops (A) to size, then seal with two coats of shellac. After they have dried, you can make a custom design with painter’s tape or a stencil. You can make different colors by blending thinned (with denatured alcohol) shellac with alcohol-soluble dyes and applying it with a Preval sprayer or paint sprayer.
Pro Tip: Frog Tape is great for creating hard lines for your design. Be sure to wipe the tape with a damp cloth before spraying the colors. This seals the edges to prevent the color from bleeding under the tape.
Step 9 - Cut The Holes
Draw a 3-in.-radius circle centered on the top (A) board’s width and nine inches down from the top. Drill a 1/4-in. pilot hole and cut out the holes with a jigsaw. Sand the inside of the hole smooth with 180-grit sandpaper.
Step 10 - Attached The Skirt
When the topcoat is dry, it’s time to attach the skirt. Put the top (A) face down on a towel to protect the finished surface. Center the skirt on the underside of the top (A), keeping it stable with a clamp while driving the 1-1/4-in. pocket hole screws. Then attach the cross braces (E) with two inch flat-head screws.
Step 11 - Mount The Legs
The legs (D) are connected to the skirt with 3/8-in. carriage bolts and held in position with threaded knobs. This allows each leg to be positioned independently to accommodate uneven yards. Gently tap the carriage bolt through the hole with a hammer. Insert a thin fender washer between the leg and the frame.
Step 12 - Install The Slip Hinges
To gang together both cornhole boards for storage, add two slip hinges and two small latches. This step is optional.
Step 13 - Attach A Spirit Level
Adding a spirit level to each cornhole board ensures they aren’t tilting to either side. We attached the levels to the top end (C) of the skirts with 3/4-in. screws. Make sure they’re perfectly parallel to the top.
Step 14 - Add Bag Storage
To store the cornhole bags, we attached an elastic net that’s used for cargo storage on motorcycle seats. Fasten the net to the inside frame of the cornhole boards with one-inch washer-head screws.
Step 15 - Add Protection
Once your design is dry, add heavy-duty protection. We applied three coats of marine spar varnish. This protects the wood from moisture and UV — and the cornhole bags inside, too!
Step 16 - Cornhole Regulation Specs
According to the American Cornhole League, regulation 312.4, section G, cornhole boards must be 24 inches wide and 48 inches long. The 6-in.diameter hole must be centered nine inches from the top of the board. The top edge of the board should sit no higher than 12 inches off the ground. Regulation cornhole bags have a smooth side and a rough side. They should be 6-in. by 6-in. and weigh between 14 and 16 ounces.
You can get some great bags or make custom bags from the American Cornhole Association.
That's it!
This is a great beginner level project that you can make over the weekend. Now go make some cool stuff and share your results with us on social!
This project is borrowed from "Family Handyman", but you can use your MARK for this fun DIY project!