Project #1: Sawhorses #1: Day 2 Update

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Blog entry by JamieH posted 09-29-2010 03:07 AM 2976 reads 1 time favorited 3 comments Add to Favorites Watch
no previous part Part 1 of Project #1: Sawhorses series Part 2: Sawhorse Complete! »

Well, I began day two of building a pair of sawhorses from the Matthew Teague “Projects for your Shop” book. I posted day 1’s progress under the Woodworking Skill Share forum yesterday. Just realized this might be better in blog form.

I got the legs cut to length with proper angles cut for top assembly, assembled the top, and screwed the legs in before I ran out of daylight. I still have end braces, stretchers, and a shelf to add. I still am having wood screw joinery issues. As you can see from pic #2 below, the leg is flush against the subtop. Look at the right leg in pic #1, and you can see it is not. Why wont all legs hug the subtop once I screw them in? I countersunk each leg screwhole. Should I have pilot hole’d the subtop? Should the drill rpms on the screw installation be slow? I am using coarse thread drywall screws. Should they be fine thread? I figured I’d build one horse at a time, so I would have to complete each step over , not mass assembly style- which would be faster. I figured this would be better practice. Any ideas/comments? Sorry for sideways pics….



3 comments so far

View JamieH's profile


52 posts in 2826 days

#1 posted 09-29-2010 03:15 AM

Oh another question, if it makes sense: Should the leg screws be parallel to the top of the horse, or perpendicular to the angle of the leg when driven? Would that make a difference in the legs tightening up?

View HerbC's profile


1764 posts in 2886 days

#2 posted 09-29-2010 03:32 AM

You should be drilling pilot holes in the piece that is being attached by the screw. In this case the pilot holes should be in the legs. The screws should be perpendicular to the piece that will be holding the point of the screw. In this case it should perpendicular to the side of the top of the horse…

Good luck.

Be Careful!


-- Herb, Florida - Here's why I close most messages with "Be Careful!"

View TreeBones's profile


1827 posts in 4050 days

#3 posted 09-29-2010 05:44 AM

I like saw horses. I’ve seen a lot of different ways to put them together. Strong is good. I like to be able to stack them one on top of the other for storage and moving. 95% of my work is done on workstations made with saw horses.

I use coarse sheet rock screws, glue and plywood gussets on Ponderosa Pine 2X4 and 1X6.

Saw Horse City
Saw Horse City

-- Ron, Twain Harte, Ca. Portable on site Sawmill Service

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