Butcher-block Cornhole Boards, Epoxy top

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Project by JohnMcClure posted 06-20-2017 02:06 AM 5637 views 2 times favorited 3 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 )

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.

-- I'd rather be a hammer than a nail

3 comments so far

View JohnMcClure's profile


1414 posts in 1922 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.

-- I'd rather be a hammer than a nail

View NormG's profile


6574 posts in 4286 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.

View Ken90712's profile


18081 posts in 4471 days

#3 posted 01-06-2020 12:41 PM

Wow, thoses are real beautys…....Love the post, new to the South and being a woodworker the good olĂ© boys at work keep insisting I make these. The have a a redneck ck list they made for me and this is it along with potted meat and so on.

I have a feeling I’ll be making a bunch of these.

recently watched The Cornhole world championship, aren’t you kidding me ? They never miss, bank shots air mail they were amazing. You won’t be seeing me there I’m guessing.

-- Ken, "Everyday above ground is a good day!"

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