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Butcher-block Cornhole Boards, Epoxy top

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Project by JohnMcClure posted 06-20-2017 02:06 AM 441 views 1 time favorited 2 comments Add to Favorites Watch

I was commissioned to build one of the finest sets of cornhole boards ever built.

I began by carefully selecting 2×4s for grain and color. I milled these to about 1.5×1.5, and laminated into 12”-wide slabs, alternating reddish and whitish boards. This is both the widest I can run thru my lunchbox planer, and the widest I can fit in my CNC.

Then I milled the outline of the cornhole, as well as the company logo. After painting the logo and planing, these started to look really good.

Next I built 4 6”-wide slabs the same way, but the outside strip is local red oak and the inside strip is a local mystery wood (Cherry, Butternut, or Sycamore – there is no consensus yet at http://lumberjocks.com/topics/226241 )

The 6” slabs laminated onto the 12” slabs created 24”-wide cornhole boards.
This was a TON of work – but it was only the beginning!

Next I made legs. These fold up, and the boards can also nest.

And then came the hardest part. Bar top epoxy on both sides of the boards.
The underside got a seal coat, and the top got a flood coat. It is beautiful – like glass!

Of course I also got some custom bean bags made.

All in all, this project was WAAAYY more work than I bargained for. Probably 5 or 6 weekends, devoting an entire Saturday or more each weekend, until this was done. Not to mention quick glue-scraping expeditions early in the AM or late at night throughout the weeks.

I learned a lot, mainly about lamination and also about bar-top epoxy. i will probably not use the epoxy on a project of this size ever again.





2 comments so far

View JohnMcClure's profile

JohnMcClure

53 posts in 306 days


#1 posted 06-20-2017 02:08 AM

I should also mention, photos do not do justice to the crystal clear epoxy. However, if I could do it over, I’d probably just lay on polyurethane very thick, and make the engraving shallow enough that it didn’t need to be filled up and leveled. Filling the engraving is one of the main reasons I thought of epoxy in the first place.

View NormG's profile

NormG

5762 posts in 2669 days


#2 posted 06-20-2017 11:21 PM

Love this game, you did a great job on them

-- Norman - I never never make a mistake, I just change the design.

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