Setting up shop #3: Work Bench Progress Pictures and Observations About Saw Horses

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Blog entry by dfdye posted 03-10-2010 06:27 PM 2621 reads 0 times favorited 3 comments Add to Favorites Watch
« Part 2: Bench Top FINALLY Going Together Part 3 of Setting up shop series Part 4: Bench is finally done! »

I finally got the pictures uploaded to photobucket, so here goes:

The legs showing the biscuits, just before glue up.
Legs before assembly

Here I am leveling the two MDF pieces on saw horses prior to glue up.
Leveling sheets prior to glue-up

Shims between the saw horses and MDF at appropriate points brought the low points up to make a dead flat surface, at least according to my cheap aluminum extrusion straight edge! (I just noticed that the shadows from the flash make it look like there is a gap at the right end of the straight edge—that is just a trick of the light. It was uniform when I took the picture.)

One other thing I have realized during this process is that my trusty 2X4 saw horses are just too bulky and get in the way more than they help. Menards had a sale on folding plastic saw horses, 2 for $10, so I picked up a couple sets, and I have to admit that they are actually not too bad. They are surprisingly sturdy given their light weight, and for the price I don’t feel as if I have to baby them. The big deal for me, though, is that they fold FLAT and I can store them easily when needed since space is at a huge premium in my 1/2 garage shop.

A side benefit that I just realized when gluing up this bench top is that they are all EXACTLY the same height! I put the 4 saw horses under the length of the bench top for glue up, and I barely had to shim anything to get things dead flat. Since I (unfortunately) rely on saw horses for temporary assembly table bases, this is quite a big deal for me. Alas, I think this will signal the end of my wooden saw horses since I can easily store 3 pairs of plastic folding saw horses in the space I had allotted for one pair of wooden saw horses.

-- David from Indiana --

3 comments so far

View stefang's profile


16058 posts in 3507 days

#1 posted 03-10-2010 07:47 PM

Looks good David.

-- Mike, an American living in Norway.

View DragonLady's profile


298 posts in 3179 days

#2 posted 03-15-2010 04:25 AM

I have 3 sets of those exact plastic saw horses from Menards, and you are right: they are surprisingly sturdy for their construction. They are not a bad deal at all.

-- A woman's work is never done-but power tools help!

View dfdye's profile


372 posts in 3209 days

#3 posted 03-15-2010 05:33 AM

Thanks, Dragonlady! I’m glad somebody else can vouch for these, least I sound like a whack-o for recommending $10 saw horses!

-- David from Indiana --

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