On 4/26/2018 5:26 AM, DerbyDad03 wrote:
My son is building a beer pong/corn hole set. Basically this:

http://www.curvesatbethany.com/wp-co.../2015/08/1.png

The circular holes need a ledge to hold the inserts.

I'll begin by saying that he already bought 1/2" plywood and cut it to size *before* he
called me about cutting the ledged holes.

So here's what I'm going to suggest:

1 - Glue a piece of 1/4" tempered hardboard to the topside of the plywood.
2 - Use a circle cutting jig and an up-cut spiral bit to cut the circular holes through the now
3/4" panel. (He's planning on making a circle cutting jig for his router)
3 - Use a slot cutting bit, with the bearing riding on the plywood to create the ledge by cutting
away the hardboard top.

A quick look shows that Amana makes a slot cutter that will cut a 1/4 inch "slot" (in this case,
the ledge) to a depth of 3/8€�. I'm sure there are other slot cuttings bits that will work.

4 - Cut the insert disks from 1/4€� hardboard.

Does that sound like a workable plan? Have I chosen the right router bits for the task?

I've never seen a cornhole / beerpong board but I've made a boatload of
cornhole sets. I like yours better.
Since I made so many and I had a steady trickling demand for them I made
a template for the hole so I could use a plunge style rabbetting bit in
my router. The template follows the outside of the router shoe (My
Porter - Cable has a round shoe profile) so I don't have the problem of
the trammel losing its center as the hole is cut. To follow the same
technique you'd have to make a ring, shimming the template to the
smaller deeper hole, then remove the ring to cut the larger hole.
Or, use 2 different rabbeting bits - one with a larger diameter. Or,
what if you used a beveled or a stepped bit? One pass and Bob's yer uncle.
I'm trying to think of another way. Nothing happened.

Steve