Instructables
Picture of How to make Cornhole Boards
To make a set of boards, you will need the following:

Materials
  • 3   96" 2x4's
  • 1   96" 2x3
  • 4   3 1/2" long 5/16 diameter carriage bolts
  • 4   5/16 diameter nuts
  • 4   5/16 diameter washers
  • 16 2-1/2 inch coarse drywall screws
  • 2   2'x4' pieces of half inch plywood (one sheet of plywood will yield four of these, they can be cut to size in the store where you buy them)
  • Primer
  • Paint
  • Water based polyurethane 
  • Putty 
  • Wood Glue
  • 1-1/2" brads

Tools
  • Chop saw or circular saw
  • Drill
  • Hammer
  • Air compressor
  • Air powered brad nailer
  • 5/16 drill bit
  • 3/8 drill bit
  • 3/32 drill bit
  • Countersink bit
  • 6 inch hole saw
  • 250 grit sandpaper/sanding block
  • putty knife
  • Paintbrushes
  • Pencil
  • Awl
  • Tape ruler
 
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Step 1: Making the Sides

Picture of Making the Sides
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To start building the frame of your set of boards, lay two 2x4's on a flat, even surface.  Take one of your pieces of plywood and lay it across the 2x4's.  Slide the plywood so that it is even with the end and the side of one of the 2x4's as shown in the first picture.  Mark the 2x4 with your pencil and cut the board on the mark.  Cut a second 2x4 to the same length.

On one end of each piece, measure 4-1/2 inches from the end of the board and make a mark.  Measure 1-3/4 inches from the edge of the board to the mark you just made, making a second mark.  At the intersection of the marks, take your awl and make a small indentation in the wood.  Next, using a drill or drill press and a 5/16 drill bit, drill through the indentation.  These holes will be used to hold on the legs.

Step 2: Making the Ends

Picture of Making the Ends
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Next, place your plywood on a flat surface and lay your 2x4's down side by side on one side of the plywood as shown in the first picture.  Take another pieces of 2x4 and lay it perpendicular to the side pieces.  At the edge of the plywood, mark the 2x4 with your pencil.  Cut the wood on this mark then cut another identical piece.
PJL0D911 months ago
Nice boards. they look like nesting ones? If you don't already, you may want to consider installing latches to keep them together during transport. I like the citadel alumni design, I'm Delta 09.
psingle1 (author)  PJL0D911 months ago
The ones in the picture are a nesting set, but I just show people how to make a standard board here. When my customers order a nesting set, I make a strap out of good old fashion Citadel webbing to hold them together! I'm Band 15.
PJL0D9 psingle111 months ago
Oh ok, that Delta set is quite nice. I intend to make a nesting set soon. I'm going to use marine latches like these, not sure which type yet. 

Rubber latch or Nylon latch
psingle1 (author)  PJL0D911 months ago
I use a strap for mine because I'm not comfortable drilling into the deck of the board with the recessed frame. Of course, if you want me to go ahead and make you a nesting set I can put some wheels on it for you! The axle holds them together.
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psingle1 (author)  PJL0D911 months ago
I actually finished these up for a Delta grad yesterday, thought you might enjoy!
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rolltidehank11 months ago
Best corn hole instructable I've seen. Well done!
psingle1 (author)  rolltidehank11 months ago
Thank you so much!
8bitMisfit11 months ago
great instructable. and your moons crooked on the red one. yea sc woot.
psingle1 (author)  8bitMisfit11 months ago
Thanks! The moon's crooked like that because the emblem is The Citadel's Big Red. It's backwards. Glad you liked it!