In this article, you will discover a video tutorial by Crafted Workshop on how to create Star Wars-themed cornhole boards/bean bag toss. The video highlights the tools used in the cornhole board build, including the Veritas Low-Angle Jack Plane. Crafted Workshop provides a step-by-step guide on the process of creating these eye-catching boards. Not only that, but you will also find out how to cut the pieces, attach the frame, shape the legs, prime, paint, and stencil the boards. Plus, there are different options for cutting the hole in the top, such as using a jigsaw, hole saw, router, or pre-cut panel. So, if you’re a Star Wars fan or just looking to add some excitement to your cornhole game, this article has got you covered!
Step 1: Cutting the Pieces for the Frame and Legs
The first step in building your Star Wars cornhole boards is to cut the pieces for the frame and legs. You will need four 8-foot long 2x4s for this build, but you can also use 1x4s if you want to reduce the weight. The plans for this build can be found in the article linked in the video description.
Cut four pieces at 48 inches, which will make up the long edges of the frame. Cut four pieces at 21 inches, which will be the short edges that connect the frame together. Cut two pieces at 18 inches, which will connect and brace the legs. Finally, cut two pieces with a 25-degree angled cut at 11 and 1/8 inches, which will be the legs of your cornhole boards.
Step 2: Optional Step to Create a Flat Surface
An optional step in this process is to cut off roughly half an inch from each 2×4. This will leave you with a perfectly flat surface on one edge of the 2×4, which, when attached to the plywood top, will give you a clean and seamless edge. If you don’t have access to a table saw or bandsaw, you can skip this step.
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Step 3: Attaching the Frame to the Plywood Top
There are two methods you can use to attach the frame to the plywood top: using vertical pocket holes or screws.
If you own a pocket hole jig, you can drill vertical pocket holes into the pieces of the frame that will attach to the plywood top. Make sure to set the depth of the pocket hole jig correctly. If you don’t own a pocket hole jig, you can simply screw the plywood top onto the frame through the top. However, keep in mind that this will leave screw holes showing unless you countersink and fill them.
Once you have drilled the pocket holes or screwed the plywood top onto the frame, assemble the frame using pocket screws and glue. Right angle clamps can be helpful during this step. Then, attach the frame to the plywood top using pocket screws.
Step 4: Cutting the Hole in the Top
Next, you will need to cut the hole in the top of your cornhole board. There are several options for doing this: using a jigsaw, a hole saw, a router, or a pre-cut panel.
Using a jigsaw is the most common method. To do this, draw a 6-inch circle on your board, drill a pilot hole, and then cut out the circle using the jigsaw. Keep in mind that a jigsaw has a flat blade, so you may not achieve a perfectly curved edge.
Using a hole saw is another option. This will give you a perfect hole, but keep in mind that they can be expensive, and you will need a heavy-duty drill to cut a 6-inch diameter hole.
Using a router with a circle cutting jig is another option. This will give you a perfectly curved cut and is a great choice if you’re making multiple sets of cornhole boards.
Lastly, you can use a pre-cut panel with the hole already cut. This is a convenient option if you don’t have a lot of tools available.
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Step 5: Breaking the Edges of the Plywood and the Hole
After cutting the hole in the top, you can use a router with an eighth inch radius round over bit to break the edges of the plywood and the hole. This will give your cornhole board a finished look. Make sure to give the entire board a final sanding.
Step 6: Marking and Drilling Holes on the Legs and Cornhole Board
Now it’s time to mark the placement of the holes on the legs. Measure the vertical center and an inch and a half from the top edge of the leg. Use a center punch or a small drill bit to mark the exact hole placement. This will help prevent the drill bit from wandering when you drill the holes.
After marking the holes on the legs, it’s time to drill corresponding holes on the cornhole board. Measure three and nine sixteenths of an inch from the top edge of the board and an inch and a half from the side of the board. Drill the holes through the board. Make sure to drill the holes as close to perpendicular as possible, using a drill press if you have one.
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Step 7: Shaping the Legs for Free Range of Motion
To allow the legs to move freely once attached to the board, you will need to shape them. You can either trace a three-inch radius and cut out the radius using a jigsaw, or you can cut two 45-degree angles on the piece that fall within the three-inch radius. Both methods will give you the same free range of motion on the legs.
Step 8: Priming, Painting, and Stenciling the Boards
Once your cornhole board is assembled, it’s time to prime, paint, and stencil the boards. Start by priming the boards and then apply a base coat of black paint. After the paint has dried, mask off the areas you want to paint in the accent color. You can use tape to create a two-inch border around the edges and a large triangle in the center of the board. Once the tape is in place, apply the accent color paint. Make sure to let the paint dry before removing the tape.
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Step 9: Attaching the Legs
The final step is attaching the legs to the cornhole board. There are two methods you can use: using carriage bolts or using fender washers and nuts.
If you choose to use carriage bolts, insert them through the drilled holes in the legs and secure them with fender washers and nuts. Make sure to tighten them enough to keep the legs in place.
If you choose to use fender washers and nuts, simply bolt the legs onto the cornhole board using the drilled holes. Again, tighten them enough to keep the legs secure.
Conclusion
Congratulations! You have successfully built your very own Star Wars-themed cornhole boards/bean bag toss. These boards are not only functional but also display your love for Star Wars. Enjoy playing cornhole with family and friends and may the force be with you! Don’t forget to follow Crafted Workshop for more DIY content.
