Building Instructions: Basic Box Style

[glorified j]

Materials

Standard 4'x8' plywood. 1/2" thick recommended. (Anything thicker is too heavy and thinner is too easy to break by a moron jumping on it!)
15'-20' 2"x2" (used internally for support, so specific lengths aren't a big deal and are cut smaller than 1', so misc pieces will work fine)
Safety glasses
Tape measure
4' long straight edge (preferably a framing square)
Pencil for marking the cutting lines
Table saw OR circular saw OR hand saw (if all you have is a hand saw, GOOD LUCK!)
RotoZip, sabre saw, or equivalent for cutting large holes in plywood.
Box of 1" or 1-1/2" wood screws (you can use nails, but screws are more secure)
Electric Drill
Mitre Saw (optional)
Cutting the 8'x4' Plywood
All the required pieces to build BOTH goals can be cut from the single sheet of 8'x4' plywood.

Click here to see the plywood cutting design

For best results, make all these cuts with either a table saw or a circular saw with a long straight edge guide. Also, keep in mind that you will lose about 1/8" of material from the cut, so cut out each section individually. The blue diagonally "hatched" section of the design is the only scrap you'll have!

Goal Design
The following layout shows how all the pieces fit together and where to cut out the hole:

Click here to see the deisgn from the side, top, and front view

There are two steps required to take the pieces from the cut plywood step and get them ready for assembly. First, take the two 1'-11" x 11 1/2" pieces and the two 1'-11" x 3 1/4" pieces and cut a 10° angle off the top edge of each piece. This will allow the playing surface to rest firmly against the frame of the goal. The next step is to cut the holes in both playing surfaces. I used a compass to draw the 6" diameter holes and borrowed a RotoZip tool from a friend of mine to make the cut. I'm definitely not a carpenter, but I'm sure there's better ways to do it.

That's it.

Thanks to http://www.suttmann.com/cornhole.php for compiling these directions!

[autoregular]

15'-20' 2"x2" (used internally for support, so specific lengths aren't a big deal and are cut smaller than 1', so misc pieces will work fine)

What do people generally use for the extra support underneath? I've seen 1x2's used, too. Any major difference?

How do you usually arrange these underneath? Running the length of the board, or in pieces?

First, take the two 1'-11" x 11 1/2" pieces and the two 1'-11" x 3 1/4" pieces and cut a 10° angle off the top edge of each piece. This will allow the playing surface to rest firmly against the frame of the goal.[/url]

Anybody have an easy workaround for this step, or something that can be done with pretty basic tools?

Thanks guys, I am planning to build a box soon, and would just like to know what's up first!

[glorified j]

Hey all. I'm building my first box style set this weekend. Just wondering if anybody had any answers to autoregulars post above, I'd be curious to know, too.

thx

--J

[osuguy0301]

I am not using any supports for mine that I am building. I am using 2"x4"s for the frame & folding legs and 1/2" sanded oak for the top. That should be plenty sturdy enough. Even if you use just 1/2" sanded plywood it should be fine. I would be afraid that supports would make the board play completely dead, JMO.

OSU