This project is by Tim Tugnachi. This DIY project not only results in a fun outdoor game but also showcases your woodworking skills.
Step 1: Gather Your Materials
To begin, you’ll need:
- Four 8-foot long 2x4s
- Two sheets of 1/2 inch plywood (2 feet by 4 feet)
- Carriage bolts
- Washers
- Wing nuts
- Handles
Step 2: Cut the Wood
Start by making three cuts on each 2×4. First, trim the ends and measure out 48 inches for the main pieces, and then cut additional pieces down to 21 inches. Save any leftover material for the legs.
Step 3: Trim the Edges
To decrease the weight, trim off the rounded edges of the 2x4s, reducing the width from 3.5 inches to 3 inches. Use a table saw for this step, and sand the pieces down to 120 grit.
Step 4: Assemble the Frame
Lay the pieces out on your workbench, clamp them together, and pre-drill holes for the screws. Use 2.5 inch exterior screws to secure the frame.
Step 5: Create the Rabbet for the Plywood
Using a router with a half-inch rabbeting bit, cut a rabbet in the top of the frame to hold the plywood securely.
Step 6: Add the Plywood Top
Once the rabbet is cut, drop in the plywood and secure it with glue and Brad nails.
Step 7: Cut the Hole
Mark a 6-inch diameter hole, positioned 9 inches from the top and 12 inches from the side, then cut it out using a router for precision.
Step 8: Assemble the Legs
Using leftover 2×4 pieces, cut them down to create the legs. Mark the center points and drill holes for the carriage bolts to attach the legs to the frame.
Step 9: Final Adjustments
Cut the legs to the final length and ensure they can prop up the board correctly. Sand down any rough edges for a smooth finish.
Step 10: Finishing Touches
Finally, sand everything down, apply primer, paint, and finish with a water-based polyurethane for protection. Don’t forget to add the handles!
Step 11: Weigh the Boards
Now, compare the weight of your new lightweight cornhole boards with your old set to see the difference!
With these steps, you’ll have a lightweight set of cornhole boards ready for your next outdoor gathering!