Making sawhorses, the easy way - Router Forums
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post #1 of 16 (permalink) Old 07-04-2016, 06:30 PM Thread Starter
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Default Making sawhorses, the easy way

Got a project coming up that I will be wanting four sawhorses for. Not going to buy any. I can make a sawhorse, but I want something simple and fast for this. I could make some simple take-apart horses from plywood, but besides taking more time than I want to spend, I don't want to use that much plywood. So, rather than trying to reinvent the wheel, google is our friend. And found this, in several places actually, but this one is possibly clearer to understand.
How to Build a Sawhorse | The Art of Manliness
I like it, simple crosscuts, no angle cuts, no detailed instructions by some idiot, and I have some old 2X4s, so don't have to buy a thing, unless I'm out of nails, not checked on that yet. For what I want, these will be about 22-24" tall probably, and maybe 2' wide. May use double headed nails, so can take them apart easily later - no screws, I very seldom, if ever, use screws for any of my work, too much of a PITA. I would possibly also make the bottom pieces maybe 6-8" or so, rather than going the whole length of the underside of the top - depends on how far my 2X4s go. I give this two thumbs, and two big toes, up.

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post #2 of 16 (permalink) Old 07-04-2016, 07:32 PM
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Nice and simple, and they look sturdy too. Wouldn't work for me because I don't have room to store them. I have four folding sawhorses with metal legs that I've used for over 25 years - probably weigh more than when new from all the lacquer overspray on them.
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post #3 of 16 (permalink) Old 07-04-2016, 11:55 PM
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I like the design Theo.

Someone I consider a master woodworker once told me that a master woodworker is not someone who never makes mistakes. He is someone who is able to cover them up so that no one can tell.
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post #4 of 16 (permalink) Old 07-05-2016, 12:08 AM
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excellent find Theo...

This would have been the week that I'd have finished chewing thru the restraints...
If only new layers hadn't been added....

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Forget the primal scream, just ROAR!!!
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post #5 of 16 (permalink) Old 07-05-2016, 04:51 AM
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Great post Theo.

Don in Murfreesboro,Tn.

Measure once cut twice and it's still to short.
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post #6 of 16 (permalink) Old 07-05-2016, 06:35 AM
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I made mine using hte sawhorse brackets and a little less of 4x2. They're great as I can collapse them down for storing. I not got a lot of room in my workshop. The timbers I use across the top are 3'6" long to support my plywood cutting table in the back yard.

When everything around you is going to pot, get out in the workshop.
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post #7 of 16 (permalink) Old 07-05-2016, 08:19 AM
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I didn't see a plywood gusset or stretcher on the legs. Maybe I missed but they are most necessary.

Learning is an exciting adventure
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post #8 of 16 (permalink) Old 07-05-2016, 08:22 AM
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A framer who used to work for us would do that first thing as soon as the lumber package arrived. But he didn't use the top of the "I-beam". I like this idea better. Thanks.

It seems I never finish what I
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post #9 of 16 (permalink) Old 07-05-2016, 08:36 AM
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In my commercial construction days the saw horses was the first thing constructed when we started a new job. Didn't have the miter saws then either so we made our own jig for that too. Two pieces of one by, a saw horse top, tri square and a regular hand saw worked just fine. Remember cutting crown molding upside down & backwards?
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post #10 of 16 (permalink) Old 07-05-2016, 08:47 AM
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I have made this type several times they work very well and very sturdy and they last a long time. They may be manly but Ladies can make them too . Just like my father made and showed me how to many years ago. I always use carriage bolts to mount the legs so I can break them down for storage.
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