HOW TO BUILD A CORNHOLE GAME
1 - 4' X 8' Piece of Plywood (pre sanded)
4 - 2" X 4" X 8' Studs (2 by 4s make sure they are not warped or twisted)
1 - Pack of Deck Screws ( 3-1/2" stainless steel square tip head)
1 - Pack of Deck Screws (1-1/2" stainless steel square tip head)
4 - 4" X 1/2" Bolts & Lock Nuts (stainless steel with washers)
Drill (with square tip bit that should come with the screws)
2 - Drill Bits (1/4" and 1/2")
Fine Sand Paper (80-120 grit)
1 - Bottle of wood glue (optional)
- 6" Hole Saw (optional)
Making The Plywood Cuts:
Start by making sure your plywood is square at the corners. You want to start at one end of the plywood and measure over 24 inches. You must measure each cut separate in order to avoid losing 1/16 of an inch due to the thickness of the circular saw blade.
NOTE: Measure only one piece at a time starting with the first piece. Only measure for the next piece after you have cut the previous piece.
Make The 2" X 4" X 8' Cuts:
Start with measuring from one end and make the first cut. Then measure the second cut and repeat the process. You should end up with 4 Pieces 4' long, 4 pieces 21" long, and 4 Pieces 12-1/2" long.
Forming The Legs:
Take the four 12-1/2" pieces and measure 1" from the end and center your mark. Place a deck screw in the center of your mark and tie a pencil to the string with the tip of the pencil at the side of the board. The string should measure approximately 1-3/4" long when tied. Now mark your round cut. Your going to remove both corners with a saw. You can round the edges with sand paper if you want them smooth. Pull out the deck screw and drill a 1/2" hole through each leg. Wait until the end of the directions to cut the angle from the end.
Building the Frame and Deck:
Note: You may want to drill out a 1/4" pilot hole before you put the frame together. This will help avoid the studs from splitting. Here is also where you can use the wood glue between each of the joints where the pieces lay together flush.
Start with your 2" X 4" X 4' and place a 21" front and back underneath at a 90 degree angle flush with each of the ends. Insert two deck screws approximately 1-1/4" from the end and side as shown in the diagram below.
Once you have completed the rectangles, place them a flat surface and mount the 2' X 4' plywood top on the frame. Make sure to start at one corner and make it flush, then insert a 1-1/2" deck screw. Then make the next corner flush with the edge of the 2' X 4' and insert a deck screw. Once you have aligned the corners continue making the sides and bottoms flush at the edges insert the remaining deck screws.
Cutting the Hole in the Decks:
Start at one end of the board and measure 9" from the end to the center of the board at 12". Place a deck screw in the center mark. Take your string and pencil and measure out 3". Keeping the string extended circle around the deck screw. If you have a ruler or paint stir stick you can drill two holes 3" apart. Place the deck screw in one hole and the pencil tip in the second hole and proceed to circle around the deck screw. Drill a hole inside the circle to allow your jigsaw blade to penetrate the deck. Carefully cut out the hole. Here is where the optional 6" hole saw can be used.
Mounting the Legs:
Lay your deck upside down on a flat surface. Place the leg one leg in the corner as shown below. Measure 1" from the end of the leg to the inside end of the board. This will allow a small space for easy swivel. You can drill from the inside of the board through the hole in the leg. Run the drill about a 1/4" into the side stud and check for swivel range on the leg. Once satisfied continue drill through the side stud. Place the 4" bolt from the outside in and put a washer and nut on the inside. Tighten the nut until the leg becomes stiff to move.
Once you get the legs mounted you can flip the boards upright with the legs in the open position and place them on a flat surface. Measure the back of the boards you will notice it is a bit higher than 12" (hopefully not lower or you'll have to remount the legs).
Here is where you fine tune your legs to be as flat as possible to the ground while making the back of the board 12" even across. Take a sander or some sand paper and shave the bottom of the leg until you are satisfied with the height. You can also apply a coat of primer and paint the boards as you wish.
If you flip your boards upside down and measure 12" from the back edge of the top of the board to the bottom of the leg and run a straight edge to the other end of the board, you can get your line to cut the leg off at the exact angle that it needs to be flush on the ground at 12" high. (See below)
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