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How to Build a Cornhole Board Set

Cornhole (a.k.a bean bag toss) is one of the most popular summer outdoor games.

To play, you simply need a set of eight corn filled bean bags and two boards. The boards can be built in an afternoon, and can be decorated with a beautiful Chuggles Cornhole Decal.

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Here’s how to build your own set of boards that will last for years to come.

MATERIALS:
1 – 2 x 4-foot sheet of ¾-inch plywood
2 – 2 x 4 studs at 8 feet in length
2 – 4-inch long 3/8-inch carriage bolts
2 – 3/8-inch nuts
2 – 3/8-inch lock nuts
4 – 3/8-inch fender washers
3-inch deck screws

TOOLS:
Miter saw
Drill
3/8-inch spade bit
Hole saw
Sanding block
Palm sander
Bean bags

Step 1: Cut the 2 x 4 studs down into useable lengths

 

  • 2 – 4-inch x 4-foot (long sides)
  • 2 – 4 inches x 21 inches (short sides)

To get the two pieces that create the fold out feet measure a length of 11 1/16 inches, then add a 27° mitered angle.

Repeat to create the other foot.

Step 2: Make the frame

To create the frame of the box take the 48-inch and 21-inch long pieces, and place in the layout of the frame making
sure that the 21-inch long sections sit inside the 48-inch long sides.

Once you’re sure everything is fit and square, pre-drill two pilot holes through each corner of the 48-inch sides and into the 21-inch length. We found it easiest to partially screw all four corners in and then come back and tighten them into place checking to maintain square as we went.

Set the completed frame aside.

Step 3: Make the top

The sheet of plywood needs a hole for the bean bags to be tossed into.

The hole we create will be 6 inches in diameter and centered 9 inches from the top of the plywood. To find the center simply measure down 9 inches from the top of the plywood sheet and mark a horizontal line across the width of the plywood.

Next find the center of this line. Since the plywood is only 2 feet wide place the mark at exactly 1 foot. The hole is easiest to create using a 6-inch hole saw and drill.

Now that the hole has been drilled, take a sanding square and smooth the cut edge. At this point you can screw the plywood top down to the frame, as always, remember to pre-drill pilot holes for your screws.

Step 4: Create the fold-out feet

The fold-out feet need some attention before we place them into the frame. In order to be able to rotate freely the top end needs to be rounded off. Measure 9 9/16” up from the shorter mitered edge and mark. Draw a horizontal line across the width of the foot and find the center of this line. That center mark serves two purposes. One is to show us the center of the half circle we will be cutting the top into and the other is to mark the location of the hole we will eventually drill for our bolt.

Use a compass centered on the mark with the radial arm taken right to the edge of the wood and circle back till you’ve created a half circle that touches both edges. Use a jigsaw and trace the outline as close as possible.

Repeat for the other foot.

Once both edges are rounded, clamp or tape them together and sand them as close to smooth and uniform as you can. We used a palm sander for ours.

TIP: It’s more important to have the edges be smooth than to match exactly.

After sanding, and while the feet are still secured together, take the 3/8-inch spade bit and use the center mark we established earlier and drill through both.

Step 5: Final assembly

With the frame and top assembly on edge, measure down 3 9/16 inches and mark the center for a hole for the hinge bolt. Again, take the 3/8-inch spade bit and drill through, repeating for the other side. Place the foot inside the frame with the shorter of the mitered edges against the plywood. Align the holes, and push the bolt through, securing with a fender washer, nut, and lock nut. Repeat for the other foot and side.

With assembly complete, feel free to go back with wood filler over any screw divots or imperfections, paint it in your favorite team’s colors, and you’re ready for a tailgate cornhole tournament.

Step 6: Add a Chuggles Cornhole Decal

Add style with ease to your new cornhole boards. Check out some of our best selling cornhole decals below.

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