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Saw Horse Panel Saw

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Project by SebringDon posted 301 days ago 2239 views 21 times favorited 11 comments Add to Favorites Watch

I wanted a safe and secure way to break down large sheets of plywood, but working from a one-car garage space is at a premium. When I saw this plan at Bob’s Plans (it’s free) I knew I’d found my solution. I made it all out of cutoffs from other projects, so the only cost was the hardware, basically some 5/16 bolts, nuts and washers, along with some furniture levelers. I even made my knobs from some scrap and t-nuts.

The first pic is a cheat from Bob’s Plans, since I forgot to take a pic of the basic setup. In the second and third pics you can see me set up to rip a full sheet of 3/4” plywood, and then crosscut the piece I ripped. The last two pictures show the “hard” part of the project, the upper clamps used to secure the plywood panel, and the lower clamps used to secure the rails to the two main supports. I think the plan only calls for four of each, but you’ll definitely need 8 of the lower clamps. I got by just fine on four of the upper clamps, though.

It fills up my carport quite nicely in use, but breaks down into a small package stored on top of a cabinet when not needed. Highly recommended if you want a simple system that doesn’t take up much room but still provides a rock-solid platform at a comfortable height.

As always, comments and suggestions for improvements appreciated.

-- Don





11 comments so far

View WayneC's profile

WayneC

12255 posts in 2698 days


#1 posted 301 days ago

Very nice.

-- We must guard our enthusiasm as we would our life - James Krenov

View waho6o9's profile

waho6o9

4749 posts in 1178 days


#2 posted 301 days ago

Very innovative, great job Don.

View PaulLL's profile

PaulLL

148 posts in 577 days


#3 posted 301 days ago

Thanks for sharing Don, I need something like this!

View scarpenter002's profile

scarpenter002

466 posts in 2506 days


#4 posted 301 days ago

Looks like a nice addition to a small shop.
Thanks for sharing Don.

-- Scott in Texas

View mjrausch's profile

mjrausch

19 posts in 456 days


#5 posted 301 days ago

got to think about doing this

-- mjrausch

View hoss12992's profile

hoss12992

2463 posts in 494 days


#6 posted 300 days ago

This is really handy. Great job

-- The Old Rednek Workshop https://www.facebook.com/theoldrednekworkshoptn

View Holt's profile

Holt

78 posts in 1230 days


#7 posted 300 days ago

My saw table was pretty much rotted out and the banquet legs were pretty worn out, so I tossed the whole thing during our latest move. This look like a better idea for the replacement., Thanks for posting!

View helluvawreck's profile

helluvawreck

15421 posts in 1467 days


#8 posted 300 days ago

That will be a nice addition to your shop. Congratulations.

helluvawreck aka Charles
http://woodworkingexpo.wordpress.com

-- If a man does not keep pace with his companions, perhaps it is because he hears a different drummer. Let him step to the music which he hears, however measured or far away. Henry David Thoreau

View BBF's profile

BBF

141 posts in 440 days


#9 posted 300 days ago

Thanks for sharing. I saw this and had to make one right away. I usually break down my panels in the barn and carry them back to the shop this now saves me that step.

-- I've never been disappointed buying quality but I have been disappointed buying good enough.

View RobWoodCutter's profile

RobWoodCutter

111 posts in 1831 days


#10 posted 300 days ago

I have done similar but not with the detail you have done here. I use the same saw horse, put a sheet of OSB on top of them and then put a sheet of 1” rigid 48”x96” pink foam board on top. That way I use the foam as a disposable cutting surface under the board I am cutting. Now that I have a more permanent 4’x8’ assembly table, I just put the 1” foam on top of it when I need to cut down something with the track saw. The 1” foam pretty much stays on the table now, because I can drill/cut into it without damaging the main top, and it has two usable sides. It is also a soft surface to sit projects on without dinging and damaging a corner or edge.

-- Rob-Yorktown "Shop's still not done, Tools are bought, Wood is bought, need to find time to start a project.."

View bob62's profile

bob62

160 posts in 1218 days


#11 posted 300 days ago

This is amazing! I have cut a lot of plywood and tried many different ways and this jig really works! Thanks

-- Robert, Mississippi, http://www.lunberjocks.com

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