Making a wooden cornhole board with custom decals requires a combination of woodworking skills and creativity. Here’s a step-by-step guide to help you create your own custom cornhole boards that will stand out at your next tailgate or BBQ.
Materials You’ll Need
- Wood: 2 sheets of 1/2″ plywood (4×8 feet)
- 2×4 lumber: For the frame and legs
- Screws: To assemble the frame and secure the plywood
- Wood glue: For added stability
- Paint: For the base color of the board and decals
- Decal material: Printable adhesive vinyl or stencils (if you’re using paint for custom designs)
- Clear coat spray: To protect the design and make it last longer
- Saw: Circular or table saw for cutting the wood
- Drill: For making holes in the board
- Sander: To smooth rough edges
- Measuring tape: To ensure everything is the right size
- Paintbrushes or spray paint: For painting the board
- Cutting machine (optional): If you’re making your own decals with vinyl
Step 1: Cut the Plywood and Lumber
Start by cutting the plywood and lumber to the appropriate sizes:
- Cornhole board dimensions: The regulation size for a cornhole board is 24 inches by 48 inches. Cut the plywood into two 24×48-inch pieces for the board’s surface.
- Frame dimensions: The frame will consist of a rectangular box around each board. For this, cut four pieces of 2×4 lumber:
- Two pieces at 48 inches
- Two pieces at 24 inches
- Leg dimensions: You’ll need four legs that are each 12 inches long.
Step 2: Assemble the Frame
- Begin by assembling the frame. Attach the 48-inch pieces of 2×4 to the 24-inch pieces using wood screws or wood glue. This forms a rectangle that will serve as the base for the plywood surface.
- Once the frame is assembled, attach the 12-inch legs at each corner. These legs should be angled at a 10-degree tilt, allowing the board to rest at an appropriate angle for gameplay.
Step 3: Attach the Plywood Surface
Now that the frame is ready, it’s time to attach the plywood to the frame. Line the edges of the plywood with the frame, ensuring it is centered. Use wood screws or nails to secure the plywood to the frame, spacing the screws about 4-6 inches apart around the edges.
Step 4: Sand the Surface
Use a sander to smooth the surface of the plywood and edges of the frame. This step will ensure the board looks neat and will help the paint or decals adhere better.
Step 5: Create Custom Decals or Stencils
At this point, you’re ready to start thinking about the custom design. There are two main ways to do this:
Option 1: Use Printable Vinyl Decals
If you’re using vinyl decals for your design:
- Create your design using graphic design software (like Adobe Illustrator or Canva). Alternatively, you can download pre-made cornhole designs from online marketplaces.
- Print the design onto adhesive vinyl sheets using a printer. Make sure the design fits within the 24×48-inch dimensions of the board.
- Carefully cut out the design using a craft knife or cutting machine.
- Peel off the backing and apply the decals to the plywood, making sure to press them down firmly to avoid bubbles or wrinkles.
Option 2: Use Stencils and Paint
If you prefer to paint the design:
- Create or purchase a stencil of your design. You can make your own by printing a design and cutting it out using a craft knife, or buy one online.
- Lay the stencil over the board and secure it with painter’s tape to prevent shifting.
- Use spray paint or a brush to fill in the design. Apply multiple light coats to avoid drips or smudges.
- Let the paint dry completely before removing the stencil.
Step 6: Paint the Base Color
Before applying the decals or stencils, you may want to paint the entire surface of the board with a base color. Common choices include solid colors or patterns like stripes or a wood stain. Let the base coat dry completely before proceeding with the next steps.
Step 7: Apply the Clear Coat
After the decals or painted designs have fully dried, it’s important to protect the design by applying a clear coat. This step ensures the artwork stays intact even through outdoor conditions and heavy gameplay. Use a spray-on clear coat for an even finish, applying 2-3 coats for optimal protection. Allow the clear coat to dry thoroughly.
Step 8: Attach the Hole Template
Regulation cornhole boards have a 6-inch diameter hole placed 9 inches from the top and centered 12 inches from each side. To cut the hole:
- Measure and mark the hole placement on the plywood.
- Use a hole saw bit or jigsaw to cut out the hole. Be sure to use a saw blade designed for cutting through wood.
Step 9: Final Touches
After the paint and clear coat have dried, do a final inspection of the board. Sand any rough spots or edges, and ensure the decals or designs are securely in place. If needed, touch up any areas with extra paint.
Step 10: Play and Enjoy
Once the cornhole board is fully assembled, dry, and cured, it’s ready for use! Grab some bags, set up your new boards, and enjoy the fun. Your custom-designed cornhole boards will be a conversation starter, and everyone will be impressed by your craftsmanship.
If you’re ready to take your woodworking skills to the next level and create more amazing projects like this, consider checking out Ted’s Woodworking Course for comprehensive plans and step-by-step guides. Click here to get started!