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I am making my first project with my newly purchased Kreg Jig Jr. I am going to attempt to make a set of cornhole boards. I found plans online, made a shopping list and came home last night with all the stuff and only then did I think, "why the heck am I following these plans to countersink screws when I just got a Kreg jig?!" Duh. So I am still going off the plans, but I plan to scratch the whole countersink idea. The frame of the set is made of 2x4s with a 1/2" piece of plywood for the top.

Now question time (no such thing as a dumb question here right?!) To make the frame, I understand that the 2x4 isnt really 2", more like 1 1/2"...So I should use 2 1/2" screws at the 1 1/2" setting, correct?? Now to attach the 1/2" plywood to the frame, what should I use? I read on here that you go by the smaller piece of woods dimensions. So would I use a 1" screw at the 1/2" setting?? Is this going to work to hold the top on, yet not poke thru?? Also, should I be using wood glue as well?
Thanks in advance for any help you can give me.

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Yes on the 2½" screws at the 1½" settings (guide and drill bit).

As for the other part, you can do a search in the box at the top-right and perhaps find your answer there, or perhaps other members who have built cornhole boards will see this discussion and give you a reply.

Type cornhole in the search box in the upper right side of the screen. The click on the search icon.  Or you can click on the link below. It will give you a list of the member's cornhole projects, photos, and forum discussions.

http://kregjig.ning.com/main/search/search?q=cornhole

Hi April - Your jig and depth collar settings are based upon the dimensions of the stock you are drilling the pocket hole in. The screw length is variable based on the stock you are attaching, ie, receiving the screw threads. Since 1/2" plywood isn't 1/2", I would start with the shortest screw possible and once you find one that actually grabs, stop. The next available length will probably go through.  For the frame the 2½" screws will work. Yes on the glue.

I would use glue on this for sure.  If you look in your owners manual for the jig it has a guideline for screw length

 

Howdy April,

I was confused about the topic of joining wood of different sizes also. Then I found that Kreg Tool has a video on that exact topic called "How To Choose The Best Kreg Screw For Your Project". At about 5:13 in the video the representative begins talking about screws for joining wood of different sizes. I found the video easy to understand and follow along with, so you might find it helpful.

You can find the video on the Kreg Tool site in their Media Center, or you can watch the video on YouTube here: How to Choose

1/8 setting with 1-1/4 screws doesn't work, haven't figured out what does for 2x4 to 1/2 plywood yet and I've been searching.

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