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How to Build a Cornhole Set With TimberTech Deck Boards

July 27, 2020

If you love DIY projects and can’t wait for warm-weather fun in your own backyard, building a cornhole set should be your next project. Check out this DIY cornhole set executed and photographed by Dunn Lumber.

TimberTech® decking was created to let you Go Against the Grain® and leave the status quo behind. That’s why, when we learned that our friends at Dunn Lumber came up with a crafty way you can use TimberTech deck boards to build a cornhole set, we knew we had to share their methods.

Whether you’re gearing up for backyard BBQs or fun-filled summer evenings, this easy cornhole set will keep the good times rolling.

A Few Notes Before You Get Started

  1. Time Needed: Dunn Lumber estimates that making one cornhole board should take 2-3 hours. Check out their Dunn DIY post on this project for all the materials, tools, and how-to you’ll need.
  2. The Right Materials: Dunn Lumber recommends using TimberTech AZEK capped polymer boards for their enduring beauty and incredible protection against the elements.
  3. The Right Color: Our TimberTech AZEK decking portfolio comes in a wide range of attractive hues, so you can put your own stamp on the project. Find your color here.

Materials You Will Need to Build a Cornhole Set

TimberTech AZEK capped polymer boards are a great fit for an outdoor cornhole set because they won’t fade, warp, or chip — even when faced with the elements. That includes the boards’ exposed ends, so there’s no need to sand or seal.

To build yourown backyard cornhole set, make sure you have the right tools and materials assembled first. NOTE: The list below will give you enough materials to build the two cornhole sets necessary for game play — just repeat the process to build your next set.

Here is what you will need to build a cornhole set with TimberTech deck boards:

Tools

  • Jigsaw
  • 12-inch miter saw or circular saw
  • Measuring tape
  • AZEK® SIDELoc™ Fasteners or 3-inch (minimum) screws graded for exterior use
  • Electric Drill
  • Clamps
  • 3/32 Drill Bit
  • Star Driver Bit

Materials

How to Build a Cornhole Set with TimberTech Deck Boards

Below is a step-by-step guide on how to build a cornhole set. Visit Dunn DIY for more information on this project.

Step 1: Measure & Cut Your Materials

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First, use a tape measure and pen to mark the 12-foot fascia board at four 36-inch sections. Next, cut the 12-foot fascia board into four 36-inch pieces. Use a circular saw or a sliding miter saw that can handle the width. Cut the two 5/4x6-foot by 16-foot boards into four 36-inch pieces and six 22-inch pieces.

Step 2: Cut the Legs at an Angle

With the remainder of the 16-foot board and a miter saw, cut four 12-inch legs at an 11° angle. Measure a foot in from the end, and mark on the edge of one side. This mark will serve as the top of the angle cut. With the leftover decking piece, measure from the top of the 11° angle and mark at the 12-inch mark. Cut straight across at this mark. Repeat until you have four legs.

Step 3: Print a Circular Diagram

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Print this 6" circle diagram from Dunn Lumber and cut it out. Fold the diagram in half. This diagram will be used for cutting the holes in the fascia boards.

Step 4: Trace Two Half Circles in the Fascia Boards

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Measure 6 inches down from the top of one of the fascia boards and use a pen to make a mark. Mark again at 12 inches. Next, place your paper circle so that each mark touches the edge of the circle, with the fold running down the middle of the circle lined up with the edge of the fascia. Trace around the paper with a pen, then repeat with the remaining fascia boards.

Step 5: Cut Circles in the Fascia Boards

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Secure the fascia board to a sawhorse or worktable using two clamps. Practice using the jigsaw to follow a traced line on scrap lumber, if you have it. Once you feel comfortable, use the jigsaw to follow the traced line on the fascia board. Composite decking cuts easily — just keep the saw steady and don’t move too quickly.

Step 6: Assemble the Frame

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Note: AZEK® SIDELoc™ Fasteners require no pre-drilling and leave a clean top. If using exterior-graded screws not specific to TimberTech AZEK decking, pre-drilling is likely required.

Assemble the 5/4-inch by 6-inch box support. Line up the shorter 22-inch pieces inside of the longer ones. Secure with two fasteners or pre-drill and secure with two screws in each corner. Line up the third 22-inch piece in the middle of the box. Secure in place with two fasteners or pre-drill and secure in place with two screws.

Step 7: Assemble the Top

Place the 1-inch by 12-inch fascia over the box and line up the ends and the two halves of the circle. Secure with AZEK® SIDELoc™ Fasteners (or pre-drill and secure with screws) in the four corners and on either side of the board, in the middle (using six screws in all). Do not drill into the screws you use used to secure the frame.

Step 8: Fit the Legs in Place

Flip the structure over to attach the legs. Place the leg in the corner, with the right angle flush against the fascia, and the top of the angle cut towards the back of the box. Drill (fasteners) or pre-drill (screws) through the inside of the leg and into the side of the frame. Secure with a 1-3/4-inch exterior fastener or screw. Repeat steps for the opposite leg.

Step 9: Start Playing

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You’ve now learned how to build a cornhole set — and have your very own durable capped polymer project to show for it. Grab some beanbags and start practicing your technique as the days lengthen, and by the time summer hits, you’ll be a champion.

All images courtesy of Dunn Lumber.

See & Feel the TimberTech Advantage

Our capped polymer and capped composite decking lines combine recycled material with all the beauty of traditional wood.

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