Cornhole Board Build Kit
To build a cornhole board, you will need a saw, screw driver, drill and a few other basic tools as well as some materials like wood and hardware and a little bit of sweat but that is it!
Whether you're a seasoned DIYer or just starting out, this project is perfect for anyone looking to add a new element to their outdoor entertainment space. With just a few basic tools and materials, you can create a high-quality cornhole board that will provide years of enjoyment for players of all ages. If you already know what you need, then jump to the step-by-step instructions.
Build Equipment
Click the pictures for
price checks on each item
After you get your equipment figured out, think about what materials you may need. To minimize costs you’ll want to buy only the minimum amount of wood needed. This can be a little tricky because material only comes in specific lengths. Also, be aware, if you never worked with wood before a 2 x 4, doesn’t actually measure 2” by 4”. There are tables that show actual wood dimensions despite what the description says. The below material list details how many lengths of each piece of wood you will need. Head to your local lumber yard or hardware store and see what they have available for stock sizes and then purchase enough to make the lengths noted.
One more note on material is the age old question: Should I use 1x4 or 2x4 wood to make my cornhole boards? 2x4 cornhole boards are better in my opinion. Yea, you will save some weight and a few dollars with 1x4s but you will also have a board that is less robust with more bounce and easier to damage. Go with the 2x4s, you’ll be glad you did.
If you already know your materials, feel free to jump to the Step by Step Build Plans.
Material List
Lumber
| Description | Stock Size | Length | Quantity |
| Frame Side | 2"x4" | 48" | 4 |
| Frame End | 2"x4" | 21" | 4 |
| Legs | 2"x4" | 11-1/8" | 4 |
| Top Sheet* | 24" x 48" x 1/2" Thick | N/A | 2 |
| Plug Material | 1" min x 24" min x 1/4" Thick | N/A | 1 |
| Leg Gap Spacer | 1" x 1" Square | 3" min | 1 |
*Pro Tip: I bought my top sheets from home depot with a pre-drilled hole in them so that I did not have to buy a hole saw that I would probably only use once. Here is the link to the corn hole top boards.
Other Materials
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Need DIY Project Help? Let me know!
Before we dive into the how to, if you ever get stuck, feel free to contact me. I have a background in mechanical engineering and have designed and built very complex machines. I am happy to help the best that I am able to via email
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Step-By-Step Build Instructions
Cut the frame pieces noted in the material list to the lengths provided in the list. You should have:
4 two by fours that are 48” long
4 that are 21” long
4 that are 11-1/8” long.
Cut the Leg pieces to the dimensions and angles shown below. This is critical to se the proper height and angle of the board when it is set up. A miter saw and miter protractor can help with these cuts but are not required.
3. Using a kreg jig, drill pocket holes in the ends of all the 2x4’s as shown. You will use pocket screws to connect 2 long and 2 short pieces together to form a box that frames the board
4. Align the top sheet onto the frame and clamp in place. Then drill mounting holes and counterbores in the top sheet to the dimensions shown in the picture.
It is recommended to drill the counterbore first with the 1/2” brad point drill bit then drill the screw holes. Drill the c’bore to .25” deep but not beyond. To be safe you may want to drill slighly under .25” deep. The plug you will cut in a later step will sit on top of the screw in the bore and then the plug will be sanded flush.
The thru hole is 1/8” diameter and should transfer from the top sheet into the frame
5. Unclamp the top sheet and add glue to the mating surfaces of the frame and top sheet, realign the 2 together, clamp in place and screw the top board into the frame with #6 x 1 -1/4” wood screws
6. Cut 24 plugs (12 per board) using the plug cutter bit (1/2”) and a drill or drill press noted in the equipment list above from the 1/4” stock material noted in the materials list.
Add a small about of glue to the counterbore and the side face of the plug then install the plugs into the counterbores as shown. Knock the plug in as far as it will go. The goal is to have a slight amount of the plug above the top board surface so that it can be sanded flush.
Once the glue has dried, sand the top board surface such that all plugs are smooth and flush.
7. Drill a:
Counter bore in both of the long frame pieces to the dimensions shown with the 1” forstner drill bit. The 4.19” dimension is from the side with the cornhole bag hole. Repeat this for both frames.
3/8” diameter hole centered on the counterbore with the 3/8” brad point drill bit. Repeat this step for both counterbores on both frames.
3/8” diameter hole in the leg pieces to the dimensions shown with the 3/8” brad point drill bit.
8. Attach the legs to the board using the shoulder bolt and nut, then set up your board as if you were going to use it. Be sure to set it on a flat hard surface such that the feet are flush with the ground. Now, using your calipers, measure the gap between the back edge of one foot and the closest frame cross member as shown
Repeat step 8 on the 2nd leg. Cut pieces of 1” square stock material to the thickness measured for each leg.
Confirm that the cut pieces are the correct thickness by sliding them into the gap just measured. If needed, sand the block to make a snug fit. There should be minimal clearance between the block, frame, and leg.
With the block slid into the gap between the leg and frame, mark the height up the leg that the block should be to fill the gap.
Remove the leg piece and glue the block into position on the leg. Do this for both legs. The leg’s final assembly should look like the picture shown. Once the glue has dried, re-assembly the legs.
9. Drill 2 holes in each frame as shown. The ø5/8” hole cutter in the 3 pack that comes with the set shown in the equipment list will cut roughly the size hole you need. Alternatively, a 3/4” drill bit will also work.
Install the rope through the holes and knot on the inside of the frame. The rope serves as a handle for the boards to ease carrying and transporting it
10. Install the rubber feet as shown with the #10 x 1” screws. It is recommended to drill a 1/8” pilot hole before installing the screws. The feet give the board something to rest on while storing it to protect the edges from damage.
