Looking for an exciting and competitive outdoor game to enjoy with family and friends? Dive into this comprehensive guide where we’ll walk you through crafting your very own wooden bean bag toss set, complete with custom-sewn bean bags. Whether you call it bean bag toss or its more common name in the South, cornhole, this DIY project promises hours of backyard fun and a rewarding sense of accomplishment. Get ready to transform your outdoor gatherings with a handmade game that everyone will love!
Once featured as a guest post for Handmade Christmas in July, this project became an instant hit. Crafting a cornhole set is an ideal undertaking for those who appreciate both woodworking and sewing – a perfect blend of practical skills and creative expression. While it may require a modest investment in materials and time, the result is a durable, personalized game that will provide entertainment for years to come. Expect to spend around $40 on supplies, especially if you have some scrap wood on hand, and many bulk-purchased items can be saved for future DIY adventures.
The beauty of building your own cornhole set lies not just in the cost savings compared to purchasing a pre-made one, but also in the ability to customize every detail. From the paint finish on your boards to the fabric colors of your bean bags, you have complete creative control. This tutorial aims to guide you through each step, ensuring a smooth and enjoyable building process, regardless of your experience level. We’ll provide clear instructions to help you create a professional-looking and regulation-sized game set.
Essential Materials for Your Custom Cornhole Boards
Before you begin, gather all the necessary tools and materials. Having everything organized will streamline your woodworking process and ensure you can tackle each step efficiently. For two standard-sized cornhole boards, here’s what you’ll need:
- Two pieces of ½-inch thick plywood, each cut to 2 feet by 4 feet
- Four, 8-foot long 2x4s (standard lumber)
- Four, 4½-inch long, 3/8-inch diameter carriage bolts
- Four, 3/8-inch flat washers
- Four, 3/8-inch wing nuts
- 1 box of 2½-inch wood screws
- Wood filler (for filling holes and imperfections)
- 1-quart of polycrylic (for sealing and protecting the wood)
Recommended Tools for Building Your Cornhole Boards:
- Jigsaw (for cutting the holes in the plywood)
- Drill (for pre-drilling holes and driving screws)
- Paint brush (for applying polycrylic or paint)
- Router (optional, for decorative edges or rounding leg corners)
- Sander (orbital or hand sander for smooth finishes)
- Measuring tape, pencil, and a compass (for accurate marking)
Step-by-Step Guide: Crafting Your Durable Cornhole Boards
Phase 1: Preparing the Wood for the Frame
Begin by cutting your 2x4s to the required lengths for the frame of your boards. You will need four pieces, each 21 inches long, and four pieces, each 4 feet long. These will form the rectangular frame that supports the plywood playing surface. Precision in these cuts is key for a sturdy and square frame. Once cut, arrange the 4-foot and 21-inch pieces to form two rectangular frames. Securely construct these frames using 2½-inch wood screws, ensuring each corner is tightly joined. Pre-drilling pilot holes can prevent the wood from splitting and make assembly easier.
Phase 2: Cutting and Attaching the Playing Surface
Next, it’s time to prepare the plywood playing surface. On each of your 2-foot by 4-foot plywood pieces, measure 9 inches down from the top edge and 12 inches in from the side edges. Mark this central point. This will be the center for your target hole. Using a compass, draw a perfect 6-inch diameter circle around this marked point. Carefully cut out these holes using a jigsaw. Take your time to achieve a smooth, clean cut, as this will affect gameplay. Once the holes are cut, place the plywood surfaces onto your assembled frames, ensuring they are flush with the edges. Secure the plywood to the frame using wood screws, spacing them evenly along the perimeter for maximum stability.
Phase 3: Building and Installing the Folding Legs
Now, let’s create the foldable legs that make these boards so convenient for storage. From your remaining 2×4 pieces, cut four sections, each 11-5/8 inches long. For stability and proper angling when set up, one end of each leg needs to be cut at a 99-degree angle. This slight angle ensures the boards stand at the correct height and lean. The opposite end of each leg should be rounded. This rounding allows the legs to pivot smoothly when folded away for storage and when deployed for play. You can use a router or a sander to achieve a nice, smooth curve.
With the legs prepared, it’s time to attach them. Drill a hole through the frame of each cornhole board where the legs will pivot. This hole should align with a corresponding hole drilled through the rounded end of each leg. Thread a 4½-inch carriage bolt through the frame and the leg. Secure the leg in place by screwing on a flat washer and then a wing nut onto the carriage bolt. The wing nut allows for easy loosening and tightening, making it simple to fold and unfold the legs without needing extra tools.
Phase 4: Finishing Touches for a Professional Look
With the construction complete, it’s time to refine your boards. Fill all visible screw holes, gaps, and any blemishes with wood filler. Allow ample time for the filler to dry completely according to the manufacturer’s instructions. Once dry, thoroughly sand your tables smooth. Pay close attention to all surfaces and edges to remove any rough spots or splinters. A smooth finish not only looks better but also ensures safer handling and consistent gameplay.
After sanding, dust your boards thoroughly to remove any residue. Now you have a choice: to keep the natural wood look or to paint them. If you prefer the natural aesthetic, simply apply a coat of polycrylic to seal and protect the wood. Polycrylic offers excellent durability and a beautiful finish. If you plan to paint, first dust and prime the boards. Primer helps the paint adhere better and provides a more even color. Allow the primer to dry, then apply your chosen semi-gloss or high-gloss latex paint. Once the paint is dry, apply a final coat of polycrylic to seal and protect your painted design, ensuring your boards can withstand the elements and frequent use.
Crafting Your Perfect Bean Bags: Materials and Sewing Instructions
No cornhole set is complete without a set of durable, regulation-style bean bags. Making your own allows you to choose colors, fabric quality, and ensures the correct weight for optimal play.
Materials for the Bean Bags:
- Sixteen, 7-inch by 7-inch squares of duck or outdoor cloth (choose two distinct colors, 8 squares per color, for easy team identification)
- Strong, durable thread
- Sharp scissors
- Straight pins
- 8 pounds of feed corn (the traditional and preferred filler for cornhole bags)
Sewing Your Own Regulation-Style Bean Bags:
Start by taking two of your 7-inch fabric squares. Place them face-to-face, ensuring the right sides are together. Sew a double-stitch along three of the four sides, using a ½-inch seam allowance. A double-stitch is crucial for durability, as these bags will endure repeated impact. Leave one side completely open for filling.
Once you’ve sewn three sides, turn each bag inside out. Use a pencil or a similar blunt object to gently push out the corners, making them sharp and neat. At this stage, your bag should measure approximately 6 inches square, ready for filling.
Now for the “corn” in cornhole! Carefully fill each bag with 2 cups of feed corn. This amount typically results in a finished bag weighing approximately 1 pound, which is the standard weight for regulation cornhole bags. The use of feed corn is traditional because it provides a satisfying “thud” when hitting the board and slowly breaks down over time, creating a unique feel. Some alternatives include plastic pellets for weather resistance, but corn is generally preferred by enthusiasts for its authentic gameplay experience.
To seal the bags, fold the raw edges of the open end inward by about ½ inch. Pin this fold securely in place. This helps contain the corn while you sew and creates a clean, finished edge. Carefully sew this final seam with a double-stitch, making sure to reinforce the ends. It’s extremely important to prevent any corn kernels from getting under the presser foot or needle of your sewing machine, as this can cause needles to break and damage your machine. Sewing slowly and deliberately, especially with heavy fabric and bulky contents, is highly recommended.
Using a heavy-duty needle for your sewing machine is critical when working with thick fabric and around corn kernels. Even with careful attention, needles can bend or break. If you plan to topstitch around the entire bean bag for extra reinforcement, proceed with caution and at a slow speed. Otherwise, focus on securing the final opening with a robust double-stitch. Repeat this process for all eight bean bags until your complete set is ready.
Your New Cornhole Set is Ready for Play!
Congratulations! You’ve successfully built your very own cornhole game set. The feeling of tossing a bean bag onto a board you crafted with your own hands is truly satisfying. Gather your friends and family, find an open space, and let the games begin! This classic outdoor activity is perfect for barbecues, tailgates, beach days, or just a casual afternoon in the backyard.
One of the best features of this DIY design is its incredible portability. The clever folding leg mechanism allows the boards to store flat, making them easy to transport to any event. No more bulky, awkward boards taking up precious space. Just fold the legs in, and you’re ready to go! This design truly makes your handcrafted set a convenient and cherished addition to your outdoor entertainment collection.
Customization Ideas to Make Your Set Unique
The beauty of a DIY cornhole set is the endless possibilities for personalization. Beyond the basic construction, consider adding unique touches to make your boards truly stand out. You can paint them with your favorite sports team’s colors and logo, create intricate geometric designs, or even opt for a rustic stained finish. Applying vinyl decals, perhaps cut with a Cricut machine, offers a fantastic way to add personalized text, monograms, or detailed graphics. These custom elements not only enhance the aesthetic appeal but also make your game set a true reflection of your personality or a wonderful gift for someone special. Don’t be afraid to get creative and explore different artistic techniques!
Safety Tips and Maintenance for Your Cornhole Set
While building your cornhole set, always prioritize safety. Wear appropriate personal protective equipment, such as safety glasses, when using power tools like jigsaws and drills. Ensure your workspace is clear and well-lit. When handling the sewing machine, be mindful of finger placement and use proper needle safety. Once your set is complete, a few maintenance tips will ensure its longevity. Store your wooden boards in a dry place, away from direct sunlight and extreme weather conditions, to prevent warping or damage to the finish. Although polycrylic provides a good seal, prolonged exposure to moisture can still take its toll. For the bean bags, keep them in an airtight container when not in use to protect the corn filler from moisture and pests. Regularly check for any loose seams and repair them promptly to prevent corn from spilling out.
Final Thoughts: Enjoying Your Handcrafted Outdoor Game
Creating your own cornhole set is more than just a woodworking project; it’s an investment in countless hours of laughter, friendly competition, and quality time spent outdoors. The satisfaction of playing a game you built yourself is unmatched. This project allows you to combine practical skills with creative expression, resulting in a durable and beautiful outdoor game that will be the centerpiece of many memorable gatherings. We encourage you to embark on this rewarding DIY journey and enjoy the fruits of your labor. Share your creations and tips with other enthusiasts, and most importantly, have fun playing!
Originally published July 29, 2011 // Updated with new text and photos on April 15, 2020.