Saw Horses or ( hey its stopped raining in Brisbane for a moment)

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Project by robscastle posted 03-07-2013 01:44 AM 2091 views 0 times favorited 2 comments Add to Favorites Watch

Well its has finally stopped raining for long enough to catch upon the back log.
Saw horses, spent quite a bit of time reading up on them whilst it was raining, along with a mathematics book on formulas relating to woodworking Pyhagoras and the likes.( really bad weather!!)

I needed some saw horses so I decided to make some, didnt want to make them too complicated and wanted to use the available timber I had.

Here is how I did it.

Saw Horses using 90 and 15 degrees
Mar 2013 Description
The Saw horses were built from recycled pallet bits, new 75 mm x 35mm Pine Stock and some 12mm plywood, either 90 Deg or 15 deg cuts were used throughout.

Radiata Pine from a recycled pallet for the top .
75mm x 35mm MGP 12 pine for the legs
12mm Ply wood, used for the leg braces.

The Top
The top is a recycled pallet section 900mm long.
The Legs
All the legs were pine 75mm x 35mm x 620mm. A length determined to match another saw horse I had.
The length really is something determined by the users choice of size.

Construction: The Top
The top is 900mm long.
The recesses or rebates were both set at 150mm in from the ends of the top and at a 15 degree angle. This angle is mirrored on each side, and is about 15mm deep, and a width to suit the legs.
Note:- Made sure you measure them to determine the real dimensions and not the nominal timber size as there may be a difference.
Mark out the cut outs at 15 deg and a width and depth to suit your timber
The top recesses can be cut on a drop saw or a table saw as the depth cut is parallel to the surface.
Material removal can be by repeat cuts with the saw or you may choose to chisel it out. The Legs The legs are cut 4x at 620mm with a 15 deg compound cut on the top and bottom.
Lay out the legs and mark out your rebate recess on 2x legs and then mirror the dimensions or replicate this for two more.
I used my tenoning jig and table saw to cut out the rebates.
You can do this on a drop saw but the ripping section you will need to either chisel it out or use a hand or power saw.

The Ply Braces
With two pieces of ply cut the braces to suit the assembly, again they are at 15 deg angles.

Fit up
Dry assembly everything and check that the saw horse sits flat and level.
It should do, there may be a slight levelling error which can be adjusted with the end braces. If it doesn’t and there is a large levelling error of which you cannot adjust out something has been cut incorrectly. Recheck and recut to suit.

  • Assembly
    Once everything is good to go,… predrill and countersink the legs. Then using decking screws assemble the legs.
    Attach the ply braces with a couple of screws only, then do a final levelling check.
    If everything is still accurate and level and its still good to go attach the ply braces with 6 x screws each side.

Hardware and tools.*
8 x decking screws 14×10x15
12 x treated screws 8-10×32
Countersink bit
Drill bit (to suit predrilling the legs for decking screws)
Compound miter saw/Drop saw and assembly bench
Table saw and Tenoning jig
Battery drill and Battery impact drill
Set Square, Pencil, Chisel and Mallet or /hand saw/power saw.

-- Regards Rob

2 comments so far

View nwbusa's profile


1021 posts in 2489 days

#1 posted 03-07-2013 10:38 PM

They look nice and sturdy, good job.

-- John, BC, Canada

View Josh's profile


1234 posts in 2772 days

#2 posted 03-22-2013 06:57 PM

All those millimeters are hurting my brain. You were reading math books to get ready to build sawhorses? Wow, you must have had long, drawn-out torrential downpours for that type of dedication! Good on ya!

-- Tree, wood, and box lover from Pennsylvania

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