This project was built and designed by Tim from Casual Builds. It’s a well-thought-out cornhole board setup that balances regulation sizing with a lighter, more portable design—perfect for backyard games, tailgates, and family get-togethers.
Tim focuses on keeping the boards strong enough for regular use while making them easier to carry and store. With a few smart construction tweaks and efficient material use, this build shows how simple woodworking projects can still meet official standards.
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A Smarter Take on the Traditional Design
Cornhole boards typically follow a set of size and height standards defined by the American Cornhole Association. Tim sticks to those key measurements while reducing the overall weight of the boards—making them ideal for on-the-go fun.
By making slight adjustments to the internal frame and hardware, Tim manages to shave off pounds without compromising playability. The result is a functional, lightweight set that’s easier to move and store than most store-bought options.
Choosing the Right Materials
The boards are made from commonly available materials, including plywood and standard construction lumber. The main structure uses durable 4×2 boards (or similar), while the top surface is cut from smooth plywood for a consistent playing experience.
To finish off the design, Tim uses carriage bolts, washers, and wing nuts to assemble the folding legs. Handles are added on the sides to make the boards easier to carry—one of several thoughtful touches that improve usability.
Getting Started with Cuts and Layout
The build begins by trimming down all the lumber pieces to size. Tim uses a miter saw to square the ends and cut precise lengths, ensuring the frame comes together neatly later on.
Even small off-cuts are saved and used to build out the legs and support blocks. This helps minimize waste and speeds up the build process.
Building a Square and Strong Frame
Each frame is laid out on a flat surface and clamped square before assembly. Tim pre-drills all holes to prevent the wood from splitting, then secures everything with screws.
He also adds a rabbet cut around the inside top edge of the frame. This allows the plywood to sit flush within the structure, creating a cleaner look and a stronger connection between the frame and the top.
Attaching the Plywood Playing Surface
The plywood top is cut to fit precisely inside the frame. Wood glue is applied around the inner edge of the rabbet before securing the plywood with brad nails for added hold.
This double-layer approach—glue and nails—gives the playing surface extra strength and prevents any flexing during play. It also ensures the top stays flat and won’t pull away from the frame over time.
Cutting the Cornhole Hole
The signature feature of any cornhole board is, of course, the hole. Tim marks the correct placement and uses a compass to draw a clean circle.
A jigsaw or router is used to cut the six-inch diameter hole. Careful sanding smooths the edge, eliminating splinters and giving the finished boards a professional feel.
Folding Legs for Portability
The legs are made from leftover lumber and cut to length with rounded ends for safety. These fold into the frame for storage, making the boards easier to transport.
Carriage bolts allow the legs to swing in and out as needed. The design includes washers and wing nuts for easy disassembly or adjustment without tools.
To improve play height and consistency, Tim carefully measures the angle so the front and back of the boards sit at regulation height. Testing the angle before final assembly ensures a proper playing slope.
Final Sanding and Protective Finish
With all components assembled, Tim gives the boards a full sanding pass. This removes any rough edges and prepares the surface for paint or stain.
He applies a coat of primer followed by paint, then finishes with a water-based polyurethane to protect the boards from scuffs, spills, and sun exposure. The finish not only looks good but helps extend the life of the boards.
Testing the Weight
After everything is finished, Tim weighs the completed boards and compares them to traditional models. His design comes in lighter, confirming the goal of building a more portable set without sacrificing build quality.
The added handles also make a noticeable difference in portability. This small upgrade turns a weekend project into a truly functional and convenient outdoor game setup.
A Project That Combines Fun and Function
Tim’s lightweight cornhole boards are a great example of practical woodworking. They’re easy enough for beginners to tackle but include clever construction techniques that give the final product a polished, professional result.
If you’re looking to build a set for summer parties or just want a solid woodworking project with a fun payoff, this one is a strong contender.
Please support Tim by visiting his website: https://www.casualbuilds.com/.