How to Construct Saw Horses
Two sturdy saw horses that are just the right height make woodworking more convenient and less uncomfortable. A height around 30 inches is common, but you may want saw horses taller or shorter. Plan custom-made ones so the tops come somewhere between your knuckles and your knees, when you're standing naturally, according to David and Jeanie Stiles, authors of "Treehouses & Playhouses You Can Build." Use treated lumber if you plan to store your saw horses outside.
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Things You'll Need
- Table saw
- 2-inch-by-6-inch-by-6-foot board
- 2 boards, 2-inch-by-4-inch-by-12-foot
- Drill
- 8 screws, 3 inches long
- 24 screws, 2 1/2 inches long
- Glue
- Screwdriver
- 1-inch-thick plywood or lumber, 10 to 12 inches wide
Instructions
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1
Cut a 2-inch-by-6-inch board 36 inches long with a table saw. Set the saw blade at a 15-degree angle and saw along both the 36-inch edges of the board so they slant outward in a shallow V, to accommodate the slant of the legs.
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2
Cut four 2-inch-by-4-inch boards each 32 inches long with the saw still set at a 15 degree angle, so each board's end slants the same way. The slanted top and bottom on these legs let them sit flat on the ground and form a flat surface on the top of the saw horse.
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3
Lay the 2-inch-by-6-inch board on a work table so the widest side is up and clamp it in place or have someone hold it still. Hold one of the legs upright against one edge of the board, aligned with the end of the board and slanting outward at a 15-degree angle so it rests against the angled edge. Drill two pilot holes for 3-inch screws, aiming through the leg and straight into the edge of the board.
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4
Remove the leg, spread carpenter's glue or epoxy on the leg where it will touch the board, replace it and insert screws into the hole. Repeat for the other three legs and wait for the glue to dry.
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5
Saw a piece of 1-inch-thick plywood 12 inches wide or use a 1-inch-thick board that's 10 to 12 inches wide. This will form a brace connecting two of the legs at one end of the saw horse. Lay the saw horse so the 6-inch-wide board is vertical and the edges of both it and the legs rest against the 12-inch plywood. Trace the outer side of both legs with a pencil and saw along the lines to create a trapezoid-shaped brace.
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6
Lay the brace against the end of the saw horse so its edges align with the edges of the saw horse and drill pilot holes for six screws, two into the edge of the 6-inch board and two into the edges of each leg. Remove the brace, apply glue to the edges and screw the brace in place with six 2 1/2-inch long screws.
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7
Saw and attach a similar brace to the other end the same way.
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8
Follow the same steps to make a second saw horse the same size.
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Tips & Warnings
For extra strength, glue and screw a 1-inch-by-3-inch board across the legs on each side, parallel to the top of the saw horse but about two-thirds of the way down the legs.
References
Resources
- Photo Credit wood saw image by Horticulture from Fotolia.com
