Take the 2x4s and using a hand saw or mitre saw cut them down into the following:
-16 inch legs (4) / 21 inch frame ends (4) / 4 foot frame sides (4)
It is very important that while you are making these cuts that you pay attention to the width of your blade. It’s easy to mess this part up, so don’t be afraid to be extra cautious with your measurements. When building cornhole boards accurate cuts are essential, so always measure twice and cut once! Cornhole measurements may vary, but these dimensions are regulation cornhole board sizes.
Your next cut is going to be on your plywood. Using a circular saw, cut down your 4 foot long piece of plywood down so it is 2 feet wide. Make sure your cut is as straight as possible so you can lessen the variability of the edges. This is going to help make your own cornhole board both easy and as close to regulation cornhole board size as possible! It is very important that if you want your cornhole board to be a regulation cornhole board, that your cuts are as accurate as possible. For those who don’t mind small variations there is wiggle room with most of these cuts.
After your precise cuts you should have two pieces of plywood, and twelve smaller pieces of wood from the cuts. Remeasure each and every piece to once and for all make certain everything is ready to be put together. These cornhole board dimensions are the regulation cornhole sizes, and intended to be used for official cornhole games as well as fun with family and friends. Make sure you are double checking your cornhole board dimensions and plans so that you haven’t left out any important pieces. These cornhole board specs will help your board look just right.
This step is very important – so read closely! Here we are going to be making your cornhole board’s wood frame. All you need are the 2x4s and 2 ½ inch wood screws. First, make sure that you have every edge and corner flush with the other boards – this is essential for getting this step correct. Some pieces of wood bend, so be on the lookout for that. Clamps can help ensure that the wood stays flush during this step. You’re going to drill a hole and then attach the screws. Double check to make sure you have attached the correct ends of the wood to one another so the dimensions come out correctly – when you’re finished your beautiful corhole board frame will look this: (picture here)
Pull out the ply wood surface. Pre drill the necessary holes on the edges and screw it down to the frame. If there is a slight difference in size between the wood frame and the ply wood that is totally OK! Just use clamps to slightly tweak the frame to fit the perfect 2×4 piece of plywood. Countersinking the screws is important during this step, so that the surface of your cornhole board has no variation. Putty or another substance is useful to ensure this smoothness later. At this step you’ll start to see your cornhole board plans coming to life!
For this step you’ll need to pull out your trusty compass. You may not have used this compass since elementary school, but you know you have one somewhere. Be gentle with it so the circle you are drawing is clean and accurate. Attach a pencil and mark the center of a hole 9” from the top and 12” from the side. These dimensions are important because if the cornhole is too far away or too close to the sides it defeats the purpose of the game. Double check your measurements before you make any cuts in the middle of the plywood or you’ll have to start all over! This is the placement of the hole on official cornhole boards and reflects regulation cornhole measurements.
Next, you’re going to drill a hole directly in the center of the circle. This will be your pilot hole. A pilot hole is important because it will allow your drilling more accuracy and be a bit cleaner. You want to make sure that you have made a nice hole with your drill so that your actual cornhole will be the right size. Can’t have a good cornhole board with out a good cornhole!
You need to be extra careful on this step – as this is the most essential part of the corn hole board! You’ll be taking your router or jig saw and cutting a regulation cornhole. Be slow and savy to the dimensions so that the edges of the hole are smooth and clean. The more precise the actual cut, the less possibility there are of variations that can make the hole an awkward size. If there are any small variations or discrepancies wrap a piece of sand paper to a cylindrical object and sand it down. You can use a thick pencil, a thick pen or anything else that will help you sand with accuracy. You can sand as much or as little as you’d like – it is important that there are no massive pieces sticking out however.
Now its time to construct the legs. It is essential that the legs of your cornhole board are accurately cut as this component of your cornhole board actually prop it up. You need to mix stability with the right size. These legs will lift your cornhole board 12 inches off of the ground. They both need to be cut at an angle and be flush with the ground for optimum stability.
Take the leg pieces you have and a pencil. Draw a line in pencil halfway through the piece, at the 1 3/4” mark. Draw a perpendicular line the same distance from the end of the leg to the first line. Here is where your compass will be placed – starting here draw a half circle that goes out onto the edges. That means that your circle will not be full and closed but will be drawn out through the edges of the wood itself.
Now you need to face down your cornhole board so the plywood is flush against the ground. You’ll need a piece of scrap wood. This scrap wood will be placed in the corner next to the leg pieces with the the pencil marks showing. Draw the hole where you will place the bolt. The leg’s midpoint on piece 1 (see picture) will have a line drawn onto the frame. The midpoint of the frames 2×4 (piece 2) from the 1 ¾ mark will be drawn together. Where they intersect is where the bolt will be placed through the center of the frame and leg.
Use your drill to drill a 3/8” hole through the side of the the table and leg. Using clamps is helpful as well as using an extra piece of wood – this reduces the likeliness of splinters or incorrect drilling. If you want you can start with a smaller drill bit and then eventually drill it with a bigger one. This will increase accuracy of hole size. Make sure your drill is always set on the affirmative setting and your drill bit is the correct size and attached properly. An improper drill can make the whole part of the project more difficult and need to be redone.
You want your leg to be able to fold outward and inward. Take the mitre saw you have available (or a handsaw will do just fine) and round out the end that you sketched out earlier. When you’re done take sandpaper and clean up the cuts. You want this to be rounded out well, but remember this part of the board will not be seen by anyone actually playing – the cornhole itself is much more important!
Get together all of your wing nuts, washers and bolts. Take your carriage bolt and slide it through the frame in the hole. Using a hammer make sure the washer and the bolt are flush with the surface of the wood. Keeping it flush here is very important. Now take all of the pieces and put them together, keeping it all tightened.
A square hole is important so that the bolt’s shoulder will fit. The bolt will sit flush and your carriage bolt will not turn when the nut is tightened. Put the washer, bolt and nut all where they need to be but don’t tighten. Ensure the movability of the leg from the position of play to the folded position. This should be easy and done without too much resistance or difficulty. You might need to trim down some wood if there is anything blocking this but if your cornhole dimensions are correct, if you followed these cornhole board plans it should be ready to go.
To be one of the official cornhole boards, your cornhole board must be 12” off the ground. What you need to do is find whatever you can to prop the cornhole board off the ground. At this point you’ll stack whatever you can find – extra wood, boxes, etc and raise your cornhole board 12” off of the ground. You’ll extend the leg into full playing position. The leg is going to be longer than necessary because there is still one final cut that needs to happen. Notice that you’ll be marking the leg diagonally so that when the cut happens it is flush with the ground. A table will work nicely to ensure this cut is accurate.
Angle your saw and cut – you want this cut to be about 45 degrees. Accuracy is important but there is a little room for error here. Do the same with the other leg. Once you’ve finished you’re going to want to do a final measurement to make sure the legs are actually 12” off the ground. This is important if you want your cornhole board plans to come to life!
To be as accurate as possible, make sure you measure the front end of your new cheap cornhole board. If it is 3-4 inches from the ground that is good, official cornhole boards must be 3 inches exactly. This small variation shouldn’t be too much of a problem for a simple home made cornhole board. Now – take a step back and look at your beautiful, new cornhole board. If everything went according to plan all you need to do now is call up some friends and family and start playing!