|Project by Rex B||posted 12-10-2013 03:49 PM||5320 views||7 times favorited||7 comments|
I made this cornhole set as a wedding gift for my cousin. They requested the “Mr./Mrs.” logos but gave me free reign over the rest of the design.
I wanted to make this set as nice and “woodworking-y” as I could, rather than just screw together some 2×4’s like many cornhole sets. I started as usual by designing everything in 3D CAD based on standard dimensions. I used a combination of thru dowels, rabbits, and dado joinery throughout. Standard size cornhole boards are huge, but I tried to make them as portable as possible by adding rope handles and draw latches to make them into one big “suitcase”. (I borrowed these ideas from Lance's awesome design.) I also borrowed the idea to add angled braces for the legs from Live4Brew's design.
The wood for this project is southern yellow pine (from 2×10’s) and 1/2” baltic birch plywood. I love using construction lumber for nice projects, to keep costs down. I started by planing all of the 2×10’s to 1.25” or 1”, depending on the part. This helped keep the weight down a bit and got rid of the crappy stock surfaces. I did end up with a ton of shavings!
I colored everything but the top with Antique Maple gel stain. I have heard many stories of gel stain blotching in pine, but I sanded everything evenly and applied the stain carefully and didn’t have any issues. The topcoat is waterborne floor varnish, for durability. My wife did the pictures/lettering by hand after the first varnish coat, then 2 more coats on top sealed them in. Prior to finish, I added my mark with a woodburning pen.
It took me way longer than most people would ever spend on a pair of cornhole boards, but I am very proud of the way these came out. The recipients were very happy with them as well. It did hurt a bit to give them away, but they couldn’t have gone to a better couple. Thanks for looking!