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During the past year set out to redesign the sawhorse.

I wanted to see if a 3-point design could be made that would solve the problem of the typical quadruped version that wobbles on uneven surfaces. I found that a 3-legged horse could be very stable.

The second photo shows how the parts were cut out of a 4×8 sheet of plywood. The photo also shows how the parts can knockdown, nest and pack flat.

I also wanted to use these sawhorses as both miter saw and table saw stands for a portable workshop. I created all sorts of components and accessories so the sawhorses can serve a wide variety of functions.

For instance, why should woodworkers in shops get all the really cool workbenches? I made a light but sturdy torsion box workbench with side and end vises that mounts on the horses.

Padded adjustable height work supports protect work.

Large holes allow for convenient clamping and hanging of tools with rafter hooks (so tools don't hang on and take up the work surface).

Gallery

Comments

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Now that is one clever design. Looks like it will work for you.
 

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Now hold it right there! You're using wood that aint all there to build sawhorses that aint all there. I'm thinking you're not all there! ;)
 

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VERY nice design!

It looks like you laminated two sheets of 3/4 inch ply together?

I'm guessing four sheets needed - around $150? Not bad!

I admire the cutouts as well - keep the weight down where not needed and provide for clamping points.

I think you are on to something here - great build.

Cheers!

-bob
 

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One of the best I've seen on LJ. Just wish the photo thing was working like it used to. Don't know how you guys come up with some of this stuff, but I'm glad you do. Looks great.
 

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Thanks Bill, PH, and Bob,

One sheet of ply per horse. I used 3/4 CDX at @20 per sheet.

I made them in pairs and used sheets with slight cupping and put the curves in opposition so they glued up nice and flat.

Best, Brian
 

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Thanks JJ,

I always tinker with things in the shop between projects and see what I can come up with.

Glad you like the ideas.

Brian
 

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great design. Simple and easy. Going in my favs. Thanks
 

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Thanks JC,

It is pretty simple… sort of the Tinker Toy of sawhorses. :)
 

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Fantastic design. Orwell was right when he said 4 legs are better than 2, but you've just convinced me that 3 legs are better than 4. Brilliant piece of work. They're cheap, functional, portable, and they look downright cool. Thanks for posting. Added to favorites.
 

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I am so making these… brilliant
 

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Lots of great creative thinking here. I love these as better horses but also for all the flexibility of function you have designed in.
Well done, thanks.
 

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I can see those at trade shows but being mass produced in a hard durable plastic for the on site remodeler. Very cool tool
 

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This is beyond cool. You should definitely take out a patent.

I could see Woodpeckers making one of these. It would be red anodized aluminum. Have built in scales on all surfaces and flip up stops everywhere. Cost 700 dollars.

Or Bridge City. It would be constructed from some exotic alloy trimmed in brass and zebrawood, featuring a built in espresso maker. Cost: just don't ask

Woodhaven would buy the patent and make it out of laminated Melamine and it would have a built in router table
 

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Very clever design! I like it. Great job.

This is not my specialty, but I just want to mention that in general a patent application for an invention needs to be filed BEFORE any public disclosure of the invention is made. Otherwise, once the information is public, the invention becomes public knowledge (prior art) and you can no longer claim the rights. I bring it up because it may be important for some of the people on this site who may be thinking of patenting their inventions.
 

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Very nice! these things will be popping up everywhere I'm sure. Does anybody know why the picture zoom and next-previous quit working?
 

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Man, that is an impressive sawhorse / workstation ! Congratulations.
 

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I think that the whole setup is not only great but very adaptable. It's what most of us need is adaptability.
 

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Now that is really interesting. Nicely thought out!
 

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This is just fantastic. Do you plan to post the torsion box workbench top as a project on here as well?

For everyone else, click the small images below to open the large images in your browser.







Let's hope the zoom function gets fixed soon.
 
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