Reply by BattleRidge

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Posted on Cutting plywood...?

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111 posts in 634 days

#1 posted 10-20-2018 02:38 AM

I appreciate the feedback thus far and am still educating myself and contemplating.

The “official” cornhole specs are for a board 47.5” to 48” x 23.5” to 24” so there is a built in allowance for cutting. I plan on simply cutting (or having cut) through the center of each board which should fit the required specs.

Lowe’s (and Home Depot) have been okay overall for most things, but again, they are what they are and results may vary. Since you don’t pay until at the check-out, should they provide a cut that isn’t satisfactory, you aren’t actually stuck with it and can simply leave it in the store – still though I don’t want to do that. If I do decide to have the boards cut, I likely won’t actually make my final decision until I am at the store and speak with the person that will be doing the cutting first – and then evaluating the initial cut before going further.

I have been partial to doing things myself – and doing it right – but at the same time cost is a factor. A track saw or new table saw is pretty much out of the picture at this point, the cost of a better / more appropriate blade is possible, a foam insulation board for a cutting surface is doable, blue painters tape no problem, zero clearance insert not a biggie, the cost of a shop-made guide / straight edge can be workable, and positioning & getting the cut right and ‘hiding’ any tear-out against the frame is very much worth the effort.

In regard to the pre-cut tops, it would certainly make the task easier and quicker, but my plans are to initially make four sets (8 boards) which would result in the cost being a little over $40 more. Being retired, time fits into the scheme of things better than the additional cost and I would rather spend the time enjoying my woodworking hobby and save the $$ to put it toward shop goodies that I can use on multiple projects and long into the future. Additionally, I would like the top to be 3/4” vs the 1/2” of the precut boards to limit the bounce, though both fit the cornhole specs if the 1/2” board has a cross support installed).

This will be a multi-step process and once the top is cut, more will follow – methods subject to change…

For the hole I may make a jig and use a router to cut the opening.

For the frame, I am looking at 2×4’s, jointing the edge that will adjoin the plywood (and possibly the outside surface for
appearance too), then connecting with glue and pocket hole screws to provide a clean and smooth appearance.

For the legs, 2×4’s fastened with 3/8” carriage bolts, washers and lock nuts.

Finish will be a combination of stain and paint – details to be determined.

Canvas duck bags probably filled with resin / plastic synthetic corn vs real corn (to limit vermin problems, moisture worries, mold and deterioration concerns).

Thank you to all who have replied and the input has been quite helpful. I’d like to have everything in order before starting and all that you have shared is very much contributing to it.

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