This is a simple instruction manual on how to create your own Cornhole Game. Be kind, this is my first instructable and my picture taking skills aren't what you would call "good."
Step 1: Getting Started
You'll need to build two gameboards, each one is 2'x4'. I used 1/2" plywood because it's still light enough to throw in your trunk, but sturdy enough it can take an accidential stomping or two. You'll also need 3 or 4 2x4's depending on how you measure and cut, and also on the final design you use.
You'll also need 1 1/2" deck screws and either 2 inch deck screws or nails. You may want to get some small hinges, but we'll get into that later.
Step 2: Start Cutting and Gluing
First: Take your 1/2 inch plywood and cut two 2'x4' boards. Many lumber yards sell precut boards of this size, and this is what I did. So far this is pretty simple.
Second: You'll need to cut 4 4 foot long pieces of your 2'x4'. I then took each one and glued it to the long side of the plywood. Make sure it's flush with the edge of the board. Clamps make this much easier. (you can skip the glue and go directly to the screwing of the board, but I had a bottle of glue around)
Third: Predrill the holes and make sure to countersink the heads of the screw. Then use your 1 1/2" deck screws to hold them in place.
Step 3: Now for the Short Sides
Measure the distance between the longer 2x4's and cut more pieces to go in between. It's going to be about 21" but remember MEASURE TWICE, CUT ONCE
Then attach them the same way as you did the first pieces. The construction part is now over half done, stand back and bask in your creating abilities.
Step 4: Cutting Your Circle
Now it's getting tricky. You'll need to measure 9" down from the top and the centerline of the plywood. Make an "X" Now you'll need a compass to draw a 6" hole. If you're like me, you lost your compass so you have to use a much cruder method.....
Take one of your screws and drill it a little ways into the board at the "X" Then take a piece of string, measure out 3" and tie your pencil at that point. Run it around the screw with the string tight to draw your 6" circle.
Now drill a hole at the inside edge of the circle, take a jigsaw or sawzall and cut out the circle. I know, it won't be perfectly straight, you'll have to either live with it or make it perfect with sand paper. The other option is to buy an expensive holesaw bit that goes out to 6inches, but this priced the project right out the window for me.
Step 5: Making Your Legs
Now it gets tricky, and since I only have 2 arms I wasn't able to get a usable picture.
You'll need to hold the top of your table up exactly 12" off the workbench tabletop, and hold a piece of the 2x4 you have left up to the underside of the plywood. Use the tabletop to mark the angle the board needs to sit on the ground flat. You'll only have to do this once because once you cut the angle, the inverse of the cut will be the proper angle for the other leg. I know, I know, it's hard to follow. I'm going to try to get a friend to help me take a couple of pics and add them later.
Now you need to decide how to attach your legs. If you want, nail or screw them onto the board and you're done! Also, you can drill a hole into the side of of your 2x and use a bolt/wingnut combo to hold them on. Then you can unscrew them for easier storage. For the ultimate in cool, get 4 hinges, build a brace between the legs, and do what I did so the legs will fold away.
Put an additional 2x4 and add it on top of the legs, remember to hack 1 1/2" off of the top of the leg so you can still have the proper 12" height. Cut a couple of 90 degree angles for extra strength and screw them on. Finally just attach the hinges to the brace and the bottom of the board and you have your ultra-cool legs that your friends will all be jealous of.
Step 6: Almost Done
You could actually call the board done now and go play. However, the board will be much better if you sand the top smooth and either finish it or paint it. You need to use a high gloss finish so the bags will slide across the board. I highly recommend putting this finish on the game because it makes it look better, play better, and you can add a personal touch. (well, you can if you have better art skills than myself)
Take some wood putty and hide your screws, also this is the time to fill in any gouges in the game top. The more time you spend here the happier you'll be.
Start sanding. Then sand some more..... keep sanding........ OK, it's smooth.
Now, if you're going to use a clear finish like me and you want to paint a logo, sports team, alma mater, etc. on the board, now's the time. The finish will help protect it. Since I have no art skills, I went straight to the finish. I used left over gym floor finish left over from an earlier project, but you can use anything as long as it finishes to a smooth high gloss finish.
If you're using a high gloss paint, start slapping it on. When it's try, add your personalization and then it's GAME ON!!!!!
MrAttorney made it!