3 Awesome DIY Saw Horses

March 4, 2020

let’s go ahead and build some saw horses!
these saw horses are so simple but incredibly useful in this video I’m
going to show you three different types that are all very quick easy and cheap
to put together while all three can be used as a standard sawhorse they are all
three made with a slightly different purpose than mine let’s go and get into
the first design which is a folding sawhorse I love this one for the shop
environment because once I’m done with them I love to fold them away and store
them on the wall I placed a handle on the top board to make it easy to carry
when it’s deployed or folded then it also has a folding tray at the bottom to
set tools or boxes of hardware on while working this design takes just a few two
by fours and a scrap piece of plywood for the tray if you’re interested in
plants or any of these I do have them available on my website there is a link
for you down below after cutting all of the legs and cross members I used wood
glue and Brad nails to make up the two leg assemblies if you’re building these
for a traveling job site and want the ability to tear them down between jobs
then go ahead and skip the wood glue however since I plan to always leave
these together and use them in my shop I apply a tight bond original to all the
joints which really increases the overall sturdiness at the end of the
build if you skip the wood glue then use screws instead of Brad Mills on these
joints alright let’s see on these up and get a quick visual check yep looks good
so let’s add on some hardware to make these guys foldable I’m using a strap
hinge at the top on both legs the main thing to pay attention here is that both
feet are flat on the work surface and that the barrel of the hinge is below
surface level I’m using a straight edge to make sure the two top planes are in
line with each other then using a pencil to mark the location of the holes this
way I can lay the sawhorse on its side and open it up to access the inside to
pre-drill and mount the head by the way in cases like this I’m not pre drilling
to prevent splitting it just makes running in the smaller screws easier now
it was originally planning on leaving them like this
but I didn’t like how the legs didn’t automatically stop at their correct
angle or how there was nothing preventing them
from just slipping out completely so next came in betray for this I recommend
using just whatever thickness of plywood you have scrap of I had some
three-quarter inch but half inch would also work fine after ripping it down at
the table saw I used a speed square to guide my jigsaw and cut out the corners
which will go around the two-by-four legs next I changed the holding
orientation in my super jaws so that I could attach a small front lip to the
front edge this lip will drop down over the bottom brace when the saw forces are
deployed and not only make the legs stop at the correct angle every time but also
stop them from slipping open when you don’t want them to these are also
attached with a small hinge then once again is to it on it to test it out it
feels great but let’s go ahead and add a top board so that we can incorporate a
handle and also just increase the surface area for putting material down
for this board you only want to attach it to the base on one side of the
horse’s or it won’t be foldable anymore I recommend countersinking me so that
the head of the screw is below the surface and a passing blade won’t be
able to hit it to make a handle I typically cheat and tear off a
cardboard handle from a six pack and then trace it on to the center and that
is it it’s easy cheap but sturdy you pick up the tray to start the folding
action then drop it to lock the legs into place and you can see I actually
did a jump test on these and they did not budge
moving on to design number two this is another folding option but in a
different direction these can be used for holding regular stock material but
where I feel like they thrive is at holding large sheet items since you can
adjust the angle of each horse to be as wide or as narrow as you need it these
are almost mostly made from two bun material but also has some scrap ply
involved working off the cut list I made I started by cutting all the parts
needed to make a pair there are a lot of repeated links so I folded out the wings
on my mater saw and used a bussy clamp and a scrap piece of wood to create
different stock blocks next I adjusted the stop block to cut
the sheet cut down into square since all of these triangles are going to be the
same I used a few pieces of tape to group them together and then cut them at
the same time at the bandsaw these are going to be the gussets or braces for
the connection at the feet to the legs to assemble I stuck the leg and foot
pieces and my superjaws use type on original again then pre-drilled and
attached with screws next I repeat it’s you out on the gusset again if you want
to break down your horse’s in the future its and skip the wood glue but if you
plan to leave them assembled then add the wood glue okay and that is the legs
done all six of them so now let’s join them together this is done with a 2×4
connecting two legs together but know how this member doesn’t attach to the
same side on the legs it’s actually mounted on opposite sides while holding
the board flush I would use a one-handed bussy clamp to hold it in place so that
I could move to the other side and get it in its position as well now I could
countersink and attach with screws next the third leg can be attached by way of
a hinge again the important thing to pay attention to here is to make sure that
the top surfaces are in line with one another and to make sure the hinge is
facing the correct direction there we go I’m just like saying so
stuff like that happens all the time the last thing to do on these horses is to
add a top plate to just widen the top surface area on this part I did skip the
wood glue so that when these get eaten up by blades they can easily be replaced
again make sure to countersink all the screws here these are gonna be the
sawhorse as I pull out when I’m wanting to break down sheet goods since the
angle can easily vary it is dead easy to support a wide board it’s worth noting
that these would also be great for a makeshift work area you know you could
throw a sheet good on top when needed but then tuck it away when work is over
for the day and then I also use it for painting or sanding larger projects such
as this named tivity scene I made for my mom already and then the leftovers for
this video is going to be a pretty standard fixed sawhorse this design has
been around for ages but it is a great one
these don’t fold but they do snap this one has a 2 by top but then one by legs
and support pieces again plans for all three are available on my website if
you’re interested I started off by cutting the ends of my 2 by top over at
the miter saw then taking it to my table saw and ripping both edges after cutting
the corresponding miter on all four of the legs I’ll use some more type on and
screws to attach them to the top this one doesn’t have a handle put in on it
because the legs are set in slightly so that there is an overhang on both ends
this gives the user a very easy way to pick one up and move it well that feels
good as is the last thing to do to really give it some strength is to add
gussets I cheat when making stuff like this I just hold up a piece of board and
trace it on both sides along the back then I could use a miter saw to cut them
to length then use glue and Brad nails to attach it and then of course I had to
stand on it so you test it out I might fall off due to poor balance but
it’s worth noting the sawhorse looks dirty okay and that wraps this up if you’re
interested in building some salt horses then I hope that this has helped you out
of course you can buy the plastic ones or even the thin lightweight metal ones
but the great thing about building your own is the ability to customize them for
the task at hand I love the ability to add in hinges beefed up the material or
make them quicker than what it would take me to run to the store and back let
me know down in the comments section which design is your favorite or if you
have a specific unique design that you’ve done for certain tasks that’s it
for this one I will see you on whatever I’m building next I want to say a big
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