Details

 HERE ARE SOME OF THE TOOLS THAT ENABLE US TO BUILD BRILLIANT-BOARDS WITH SUCH PRECISION

Here’s the details of the photos in order left to right:

  1. INCRA MITER EXPRESS POSITIONER with Angle Lock Indexing to 364 Positive Stops adjustable to 1/2 degree increments.
  2. INCRA Offset Router Table including the outstanding MagnaLOCK Aluminum Router Mounting Plate
  3. Special Edition Telescoping INCRA-LOCK Fence – This Special Edition Miter Fence telescopes from 36″ to a full 64″ length
  4. Incra Miter 5000 Miter Sled.
  5. INCRA Wonder Upgrade for the INCRA LS Fence System with Joinery Package
  6. The INCRA LS Positioner with the patented steel lead screw positioning system to instantly snap the fence to the dead center of any multiple of 1/32″
  7. The Full LS Super System with the Wonder Fence Upgrade including the Joinery Package
  8. All the INCRA Precision Systems sit mounted to the Grizzly G1023RLWX 10″ Cabinet Saw featuring a 50 amp/ 5 HP Motor with dust collection at every power tool in the shop.

NEW IMPLEMENTED IMPROVEMENT

As always, I am looking for ways to improve, with the plywood inlaid into the maple sides and ends we are limited to the type of joint at the corners we can use, so that the plywood edge stays hidden behind the attractive maple. So now we utilize one of the strongest glue joints in woodworking, the reverse rabbet joint. This joint has almost twice the gluing surface making it much stronger than the miter joint. Now this, combined with the added strength from the diamond plate corners, you can be sure that you have the sturdiest set of boards on the planet, Brilliant!

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OUR BOARDS AREN’T JUST A PRETTY FACE…… THEY’RE FOREVER!

What you will not find with a set of our boards is a slab of plywood slapped on top of pine 2×4’s with no cross bracing underneath. Cornhole boards are exposed to the elements that can damage the boards, namely humidity and moisture. By placing the plywood “on top” of the frame instead of inside it, you’ve just exposed the the most vulnerable area of the boards to the elements , the edge of the plywood. You see, the edge of the plywood is like a funnel for moisture because the edges are the ends of the wood fibers, the “end grain”, kind of like if you stacked a handful of wooden toothpicks on their end. Yes they will be protected the day your boards leaves the shop by the paint or polyurethane, however one scratch or dent on the edges and you’ve created an alley for moisture to enter and start the destruction of the boards you paid good money for.

See in the photo below that we have then entire edge of the plywood buried behind the hard maple sides and we set them in a bed of glue when assembled, not to ever be separated from the sturdy maple frames. The boards we currently play on are the Redskins boards in our gallery that have the black redskin logo, they are in their 5th year of existence, they have been through a 1400 mile move to Texas and I can’t count how many tailgates and still today they play just like the day we built them.

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This is the final result after everything is assembled. Once painted we have created an invisible seam!

 

We've been asked, "Why Maple, wouldn't it be cheaper to use something else?" Our answer is " Yes, it would be and that is exactly why we don't". Maple provides the strongest and straightest material we could use that is resistant to warping and cracking.

We’ve been asked, “Why Maple, wouldn’t it be cheaper to use something else?” Our answer is ” Yes, it would be and that is exactly why we don’t”.

Let’s look at some comparisons between “Maple” what we use and “Pine” what most others use:

Lumber is tested in a number of ways below is just a couple comparisons:

1. Impact Bending – This test is performed by dropping a 50lb hammer from successively increased heights until rupture or complete failure occurs. Pine Fails at 513 inches or roughly 43 ft, now Maple fails at 1026 inches or 85.5 ft!

2. Janka Hardness – This measures the resistance of a sample of wood to denting and wear. It measures the force required to imbed an 11.28mm (.444 in) steel ball into wood to half the ball’s diameter. This method leaves an indentation. Pine only needs 420 lbs to embed the steel ball, now Maple requires 950 lbs!

Now I ask you, would you like your hard earned money spent on Pine or Maple?

This is where our boards are born, from the finest rough cut maple.

This is where our boards are born, from the finest rough cut maple.

This is enough rough cut maple to create all the parts for (4) sets of boards.

This is enough rough cut maple to create all the parts for (4) sets of boards.

The first thing we do is mill the rough cut lumber with a thickness planer, which creates a perfectly flat board to make the parts with. No warped or cupped boards like you will get when using machined lumber at the big supply stores.

The first thing we do is mill the rough cut lumber with a thickness planer, which creates a perfectly flat board to make the parts with. No warped or cupped boards like you will get when using machined lumber at the big supply stores.

Okay all maple has be thickness milled to a "Perfect" 3/4". Typically lumber from you big chain stores will be slightly thicker that this, with the material milled to exactly 3/4" it makes for very accurate pieces so the fit of the parts is very precise, making for a high quality results.

All maple is thickness milled to a “Perfect” 3/4″. By milling to exactly 3/4″ it makes for very accurate pieces so the fit of the parts is very precise, making for a high quality results.

Okay we have a perfectly flat piece of maple, but we do not have a perfectly straight edge. We solve this with our Incra Wonder Fence Positioner and a straight router bit.

Now that we’ve planed the material we have a perfectly flat piece of maple, but we do not have a perfectly straight edge. We solve this with our Incra Wonder Fence Positioner and a straight router bit.

Here mill a few thousands of an inch at a time until the entire length of the board has been milled and is perfectly flat.

Here mill a few thousands of an inch at a time until the entire length of the board has been milled and is perfectly flat.

As you can see we now have a perfectly straight edge to start working from to produce precisely machined parts

As you can see we now have a perfectly straight edge to start working from to produce precisely machined parts

Okay now we have perfectly flat material with one perfect edge to start working from

Okay now we have perfectly flat material with one perfect edge to start working from

Assembled Ready for the Design and In the spray booth ready for sanding sealer

Assembled Ready for the Design and
In the spray booth ready for sanding sealer

Its quite a timely process just for stripes but there’s no short cuts for quality!

All of our striping colors, whenever possible, are the actual official team colors utilizing the Glidden Official Team Colors brochure. We purchase samples of Glidden colors and make a color sample board then have Sherwin-Williams match the color for us. All our boards feature Sherwin-Williams paint.

We inserted a bubble level in the cross brace that, when installed is calibrated with the playing surface above, to ensure a level playing surface at all times.

We inserted a bubble level in the cross brace that, when installed is calibrated with the playing surface above, to ensure a level playing surface at all times.

We use a stainless steel spring loaded locking latch to keep the boards securely nested together during transport.

We use a stainless steel spring loaded locking latch to keep the boards securely nested together during transport.

Here we have an un-level surface, but yet we are able to provide a level and true playing surface utilizing our independently adjustable legs.

Even on this slope the boards play just like they were on level ground!

Completed and ready for delivery to the new owners…

 

 

 


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