Saw horse made easy

Comment

Comment by Robert Brennan on March 7, 2013 at 1:44am

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.

 

Materials:

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.

 

Dimensions:

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 x 10 x 50

12 x  Treated Screws 8-10 x 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.