DIY Network

Sawhorses Create a project you can really build on. From "B. Original" episode DBOR-510

Every workshop needs a sturdy pair of sawhorses.

Sawhorses are workhorses: They support large pieces of wood for sawing. They hold a piece of plywood for an additional work surface. They even make an out-of-the-way place to rest a soda.

Michele Beschen prefers good, old-fashioned wooden sawhorses to the metal or plastic ones available at the store. Build a pair with her in this easy B. Original how-to. You'll end up with tough, attractive sawhorses that will support any project; scroll down to get started.

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Sawhorses

Materials:

(4) 2x4 boards, 8' long
(4) pieces of 1/2" plywood, 10" by 7-7/8"
miter saw or hand saw
adjustable bevel square
safety glasses
1-5/8" drywall screws
drill with screwdriver tip
3/16" wood bit and 7/16" wood bit
3" decking screws
wood glue

Figure A

• Each leg on the two sawhorses will measure 31" with a
  22-1/2" degree angle on each end.

• Set the miter saw angle to 22-1/2 degrees. If using a hand saw, use a protractor or other measurement for 22-1/2 degrees.

• Place a 2x4 on edge and make the angled cut on one end (figure A)

  Safety Alert: Always wear eye protection and use extreme caution when using a power saw or power drill.

• Measure and mark 31" from the longest part of the angle cut. Cut the other end with the shortest part of the angle cut is at the 31" mark.

• Cut the other seven legs in the same manner.

• Check to make sure the adjustable bevel square is set at 22-1/2 degrees. If using a miter saw, check the square against the miter saw.

• Lay out one of the pieces of plywood and line up the bevel square on the 10" side of the plywood, in the corner. Mark a cutting line along the bevel square.
  

  	Figure B
  	Figure C
  	Figure D
  	Figure E

• Flip the bevel square over and mark a cutting line in the other corner of that side (figure B).

• Check the measurements and cutting lines: They should make a trapezoid that measures 10" on the bottom and
  3-1/2" on the top.

• Cut out the trapezoid with a hand saw or band saw (figure C). Repeat for the other three pieces of plywood. These plywood gussets will hold the legs of the sawhorses in place.

• To assemble the legs, place two legs on edge on the work surface with the tops touching. Lay them so the angle cuts at the top line up to make a flat surface.

• Position a plywood gusset on top of the legs. Adjust the legs until the gusset is flush with the tops and sides of the legs.

• Attach the gusset with wood glue and four drywall screws along each side (figure D).

• Flip the leg assembly over and attach another gusset on the other side.

• Assemble the other three leg sets in the same manner.

• Cut two 2x4 pieces 42" long with a straight cut on each end.

• Use a 3/16" wood bit to drill pilot holes in each end of both boards. These should be 6" in from the end of the board and 3/4" in from the sides.

• Use a 7/16" wood bit to drill down into the pilot holes, only going about halfway through the board. This provides a way to recess the screws and keep them out of the way when the sawhorses are in use.

• Secure the boards to the finished legs with wood glue and 3" decking screws (figure E).

• Let the glue set up, and you have a set of wooden sawhorses that will last a lifetime.