Woodsmith Super Sawhorses

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Project by HappyHowie posted 10-07-2015 09:23 PM 4242 views 24 times favorited 5 comments Add to Favorites Watch

I needed new sturdy sawhorses after giving my store bought ones to my son-in-law. After reviewing several plans I chose Woodsmith’s Super Sawhorse plan. This was fun to build. The project also gave me an opportunity to practice some joinery techniques with bridle joints, through tenons, etc.

With these sawhorses I can easily clamp my outfeed or side support jigs to them for use with my table saw, or drill press or bandsaw.

-- --- Happy Howie

5 comments so far

View luv2wheels's profile


39 posts in 1387 days

#1 posted 10-08-2015 12:20 AM

Very nice. I have milled parts to build a pair, but not as beefy as yours. Saved in my favorites because of
the out feed idea.

-- too old to rock & roll......

View TopamaxSurvivor's profile


18425 posts in 3916 days

#2 posted 10-08-2015 12:42 AM

Looks like they should serve you well. The out feed idea caught my attention too! ;-)

-- Bob in WW ~ "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

View HappyHowie's profile


471 posts in 2185 days

#3 posted 10-08-2015 02:41 AM

Thank you guys for your kind comments.

I do really like these sawhorses; especially for their size and sturdy stance. I believe I bought and made all of this from eight Douglas Fir 4 by 4 by 8 feet long posts. Their actual dimensions were more like 3 5/8” by 3 5/8” by 8 feet in the box store I bought them. I also looked at some redwood posts but they had slightly smaller dimensions and redwood is a softer wood type. That is why I ruled that wood out. I did consider using poplar and probably gluing several strips to get rough sizes like 4” by 4”, but the cost calculated to be more costly than I wanted to go. These Douglas Fir sawhorses will last several lifetimes, I believe. I have protected the wood with two coats of Tung Oil and rubbed loads of paste wax on its surfaces…

The 2 by 2 by 2 deep mortises and fitting tenons on the posts are very beefy. And, the bridle joints on the bottom of the posts and how they straddle the foot braces are again a very strong joint with a lot of timber to hold it firm. I could pin them with a dowel piece. I will think about that.. Then on top of that the stretcher is big, thick with it’s through tenons (that I also could pin) they give the sawhorses a sturdy stance and even make it look way cool.

If you build them I hope you have as much fun as I did making them. Plans are available from Woodsmith Shop Notes. I subscribe to their entire library which I believe is a good deal; the Super Sawhorses plans are in Shop Notes #108, pp 34-37. That said you could probably draw up plans for yourselves by just guessing at the dimensions on my sawhorse. and beams.

Best wishes.

-- --- Happy Howie

View waho6o9's profile


8539 posts in 2817 days

#4 posted 10-08-2015 04:21 AM

Most excellent saw horses, congrats Howie!

View JimInNM's profile


316 posts in 1456 days

#5 posted 10-08-2015 02:45 PM

Very nice, I would definitely consider putting dowels at different heights to match outfeed and workbench levels to increase versatility. They are too nice to limit or constrict usage..

-- JimInNM........Space Case

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