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How Flatiron Cornhole Boards are Manufactured

Flatiron boards are produced at the Flatiron Cornhole manufacturing facility in Arizona. Our production process begins here with this state-of-the-art automated machinery that transforms premium plywood into the precision parts required by our unique board designs.



  1. First we select high grade 3/4" plywood. 13-ply Baltic birch is our material of choice due to its strength and consistently clean appearance. The quality of the plywood is one of the most important keys to quality game boards. It has to be strong inside and out. You get what you pay for with plywood. If you're making homemade boards you'll probably have to settle for what you can get at big box hardware stores, and it just might be ok if you select it carefully. If not, you're only out a small cost. But if you're buying a set of boards you expect more. After working with different grades of plywood, we as players would never pay for boards made of the cheap stuff, so we cannot justify selling it, even it if would mean lower prices and higher profits.
  2. The plywood sheet is mounted on the bed of our 3-axis CNC wood router where powerful suction grips it firmly in place.
  3. Once the CNC router is programmed with the design for the parts that make up a particular model of cornhole boards, it begins the precision operations that will lead to the finished pieces. It drills holes, prepares edges, cuts grooves, carves out pockets, slopes in and out of deep cuts, and finally circumscribes each complete piece and cuts it free. All of this is accomlpished with a variety of specialized tools, each capable of an accuracy approaching the width of a sheet of copy paper.
  4. When all of the pieces have been cut, they are extracted from the remains of the sheet. Very little material goes to waste! Each piece is the cleaned, deburrred, sanded, and prepared for assembly.
  1. Many pieces require further preparation before assembly. Hinge holes are counterbored, thicker pieces are layered together, corners are squared, smaller pieces are hand-cut, and the Flatiron logo is proudly added.
  2. Next we round over all the exposed edges with two special routers, a router table, guide jigs, and several different bits. Each final piece is then hand-sanded again to smooth out any rough spots left by the power tools.
  3. At this point the playing surfaces are given special attention. They need to be especially smooth and flat in order to look and play just right. This requires four passes of sanding with increasingly fine sanding and polishing tools. It starts with a palm sander, then a random orbital sander, and finally gets completed with hand-held sponges and pads.
  4. Assembly of the prepared parts is easy due to the precise shapes and careful design of the parts. Once they are arranged and dry fit, it's just a matter of proper gluing, cleaning, clamping, and reenforcing.
  5. Next the boards and leg assemblies are given a final sanding and cleaning. Then they're taken to our spray booth where they are given a mirror-smooth UV-protected clearcoat, several coats thick.
  6. Legs, hinges, feet, corner guards, and latches are added. And after a final inspection and cleaning, the boards are ready for play.




 
   
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