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Saw Horse Panel Saw

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Project by SebringDon posted 09-29-2013 05:55 PM 2491 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

12302 posts in 2845 days


#1 posted 09-29-2013 05:56 PM

Very nice.

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

View waho6o9's profile

waho6o9

5286 posts in 1324 days


#2 posted 09-29-2013 06:02 PM

Very innovative, great job Don.

View PaulLL's profile

PaulLL

158 posts in 724 days


#3 posted 09-29-2013 06:21 PM

Thanks for sharing Don, I need something like this!

View scarpenter002's profile

scarpenter002

502 posts in 2652 days


#4 posted 09-29-2013 09:39 PM

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

-- Scott in Texas

View mjrausch's profile

mjrausch

20 posts in 603 days


#5 posted 09-29-2013 10:11 PM

got to think about doing this

-- mjrausch

View hoss12992's profile

hoss12992

2957 posts in 640 days


#6 posted 09-30-2013 06:23 AM

This is really handy. Great job

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

View Holt's profile

Holt

80 posts in 1377 days


#7 posted 09-30-2013 04:01 PM

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

16033 posts in 1614 days


#8 posted 09-30-2013 04:03 PM

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 586 days


#9 posted 09-30-2013 04:57 PM

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 1977 days


#10 posted 09-30-2013 05:03 PM

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 1365 days


#11 posted 09-30-2013 05:05 PM

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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