Looking for a fun woodworking project that will impress your friends at your next backyard gathering? These cornhole boards were designed and built by JKM Woodworking, and they’re packed with cool features like beverage holders and stylish box joints.
Materials and Tools Needed
- 4′ x 8′ sheet of birch plywood
- Dimensional select pine (3.5 inches wide)
- 2×4 lumber for legs
- Wood glue
- Shellac
- Denatured alcohol
- Spray paint (in your color choices)
- Paint tape
- Carriage bolts (3 inches)
- Brad nailer
- Dado stack for box joints
- Router
- Saw (circular and miter saw)
- Drill
- Sander (orbital and bench sander)
- Jigsaw or hole saw (for cutting holes)
Step 1: Cutting the Plywood
Start by cutting down your 4′ x 8′ sheet of plywood. This birch plywood has a thin veneer that can splinter easily, so use a two-cut method: first, make a shallow cut just through the top layer to score the plywood, then follow up with a deeper cut all the way through. This will help you achieve clean edges with minimal splintering.
Step 2: Preparing the Frame Pieces
Now, cut the frame pieces using a miter saw. Set your stops at 47 5/8 inches for the long pieces and 23 5/8 inches for the short ones, allowing for a slight overlap. Use select pine for the frame, which should already be 3.5 inches wide.
Step 3: Making Box Joints
Using a box joint jig and a dado stack, cut the joints for the frame. Make test cuts on scrap wood to adjust the height and ensure a snug fit. This process is meticulous but essential for a strong connection.
Step 4: Assembling the Frame
Before gluing, sand the inside of the joints to ensure a smooth finish. Apply wood glue to the end grain, allow it to soak in for a few minutes, then assemble the frame. Use clamps to hold everything together while the glue dries.
Step 5: Attaching the Top Boards
Once the frame is dry, attach the top boards using glue and a brad nailer. To prevent glue smearing, use temporary alignment blocks to position the top boards accurately.
Step 6: Cutting the Cornhole Holes
Measure 9 inches from the top and drill a pilot hole to mark the center for the 6-inch hole. Use a hole saw for a clean cut, then round over the edges with a router.
Step 7: Making the Legs
Cut the legs from 2×4 lumber and use a planer for a smooth finish. Round off one end of each leg and drill a hole for mounting. Ensure the legs are angled correctly for stability and functionality.
Step 8: Adding Beverage Holders
Cut holes for the beverage holders using a 3-inch hole saw. Sand the edges to smooth them out and attach them to the legs using pocket hole screws.
Step 9: Finishing Touches
Seal the wood grain with a shellac mixture before painting to avoid bleeding. Once dried, sand the surface and apply your chosen paint. Use stencils for clean designs, and finish with a water-based urethane for durability.
Step 10: Assembly and Final Details
Attach the legs using stainless steel carriage bolts and add any additional features like scoreboards. Now your cornhole boards are ready for a fun day at the park or backyard!
With these steps, you’ll have a beautiful set of cornhole boards that are perfect for any outdoor gathering.