This is a fun project and ideal for very special gifts, great for your own backyard. ; probably best suited for DIY person who is used to dealing with wood projects and the tools recommended. Ask the experts at Dolan’s Home Improvement Centers in Concord and Pinole for help selecting the tools and materials you may need.
Before you build your Conhole boards, go to the ACL (league) website for legal specs. They will match the following instructions.
TOOLS NEEDED:
Circular or Chop Saw
Power Drill
6″ Hole Saw
5″ Orbital Sander (or Light Sand Paper)
Staple Gun
Two Clamps, 6″ or 12″ Long
Kreg Jig (Optional)
MATERIALS REQUIRED:
1/2″ or 3/4″ Birch Plywood
Four 2x4x8 wood pieces
Four 1/2″ Galvanized Carriage Bolts
Four 1/2″ Galvanized Washers
Four 1/2″ Galvanized Wing Nuts
Sixteen 3-1/2″ Kreg Screws
Wood Glue
Wood Putty
Pencil for marking
Measuring Tape
INSTRUCTIONS: Make sure you have everything you need. Sort your materials and check your tools according to the lists above.
- Take two of the 2x4x8s and cut each one 48” long with the miter saw that allows for a clean straight cut. You should now have four 2×4 pieces that are 48” long.
- Take the two remaining 2x4x8s. Cut each board into two 21” long pieces and two 11½” pieces. You should now have a total of four 2x4x21” long and four 2x4x11½”.
- To create the legs using the circular saw, round off the top edge of each of the 2x4x11½” by cutting off the two corners.
- Build a rectangular box with two 2x4x48” boards and two 2x4x21” boards. Using the jig and drill pocket holes near the ends in the 2x4x21”. The 2x4x21” boards will screw into the 2x4x48” boards forming a frame that measures 2’ x 4’. Repeat with the remaining 2x4x48” and 2x4x21” boards.
- Apply wood glue on the top edge of the framed boxes and lay the birch plywood on top of each frame. Using your staple gun, staple (or nail) plyboard to the frame setting a staple (or nail) every couple of inches.
- Next, cut the holes in the birch boards. Proceed slowly and carefully. Using the corded drill and 6” hole saw, drill a hole into the plywood 12” from the 24” edge and centered. The drill bit center should be 12” from the 24” side of the board and 9” from the top of the 48” sides. The edge of the circle cut should be 6” from the top edge of the plywood. Be sure you drill a hole into both plyboards.
- Turn each box over and lay the 2x4x11½” boards inside the framed boxes with rounded edges in the framed corners and sides flush with the 48” sides. Make a mark 1” from the rounded top edge and the center mass of the 2x4x11 ½” board. Make a mark on all four 2x4x11 ½” boards.
- Using the drill and a ½” drill bit; drill a hole center near the rounded edge in the 2x4x11½” boards. Try to align holes on each side of the boards. The boards should sit flush.
- Place 2x4x11½” pieces back into position and mark through the hole of the 2x4x11½” boards onto the 48” sides.
- Using the drill and the ½” drill bit; drill holes into all four 48” side boards.
- Insert ½” galvanized carriage bolts from the outside through the 48” sides and through the legs.
- Add a ½” galvanized washer on the end of bolt, then screw on the ½” wing nut tight until the head of the ½” galvanized carriage bolt sinks into the frame. Repeat until all legs are attached to each boxed frame.
- Apply wood putty over any exposed staples or nails and let dry.
- And now, it’s time to sand. Using the 5” orbital sander; evenly sand the top and side surfaces of your corn hole boards. Use nothing heavier than a 120 grit sandpaper. Make sure to keep the veneer intact.
- We recommend sealing your accomplishments with a clear coat or apply a painted design.
TO PURCHASE BEAN BAGS FOR YOUR GAME: Search the Internet for “cornhole bean bags (add your zip code)” and you will discover a host of on-line and in-store companies. Make sure you order regulation size.
- Bags must measure 6 inches wide and 6 inches long (±1/4 inch).
- Bags must weigh between 15.5 and 16.25 ounces.
- Bags must have a thickness no less than 1.125 inches and no greater than 1.5 inches.
Now you’re all set for gift-giving and outdoor fun.
