instructables

Folding Sawhorses, Simple and Handy!

by Pahoolo1

Here is a simple woodworking project that only jobs. requires a few simple tools, and some basic skills. When not in-use, you can hang them on hooks, lean These folding sawhorses are easy to build, them against the wall, or lay them flat and slide them lightweight, sturdy, and very portable! They use under something. common hardware, straight cuts, and standard lumber. They also fold flat for storage and are tougher It seemed like a good starter project. then they look! .Even with “one-by” dimensional lumber (1x4” or 1x6”), they are plenty strong for most

Folding Sawhorses, Simple and Handy!: Page 1 Step 1: Why You Would Want Some of These!

Most people underestimate how useful a sawhorse is. accommodate taller people, (who have access to But actually, having one or two on-hand can make a power tools). big difference! The original plans for a "carpenter’s sawhorse" called for it to be at about 24” tall. This A really handy size for these is about 3’ tall and 2’ would put it just about “knee-high” and basically made wide. in this size, they can fold up and fit into a it easier for a carpenter cuting downwards with a normal closet. You may notice that the build pictures Handsaw. It was also common to brace boards with a show me assembling a pair that are actually 48’ wide. knee while cutting, so that was a good height back I made these for a particular project involving plywood then. sheets, but other then that, the process is the same.

Modern sawhorses are usually a bit taller, mostly to

Step 2: Stuff You Will Want/need to Actually Make These!

Now theoretically, a person COULD just build these --Tape measure, yardstick, ruler, (whatever you have) using only a hand-saw and a screwdriver for tools. -- Screw driver, or power Drill/Driver (a #2-Phillips tip But I’m basically lazy, (and I DO have all these power is standard). tools laying around). -- About 18” of cord or light chain, for the legs. = Recommended tools: -- A sharp Pencil, with an eraser, (always a nice option). -- Hand Saw, Circular Saw, or Power Miter-Saw (my favorite) -- Basic protective gear, (Glasses, gloves, ear-plugs, Band-Aids). -- Framing square, or Speed-Square (for right-angles)

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1. "Old Reliable" My trusty old 1. Ultra-handy "speed-Square", not actually necessary, but as I said, Handy! power miter saw! you don't really need this, I'm just bragging.

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1. Power-drill, also doubles as a screw-driver! 1. #2 Philips heat driver tips for the drill. I have since upgraded to an impact driver, (and I highly recommend you get one).

Folding Sawhorses, Simple and Handy!: Page 4 Step 3: MAterials! Wood Mostly.

First, a quick comment about dimensional lumber slightly longer. This allows you to “True up” the end of (and you may already be aware of this); the board, (correcting any crooked end-cuts). Don’t let this worry you though, remember that part about “no Lumber measurements are “Nominal” which basically critical measurements”? means “NOT specifically accurate”. For example: a “1x4” board is actually ¾-inch thick and 3 ½-inches Materials: wide. The actual length of a board is also usually

For EACH 3’ high/2’ wide sawhorse, (double the You need about 16 for each sawhorse. recipe for pairs) you will need: -- Wood-glue, I usually recommend using wood glue --Two 6ft. 1x4” boards, (cut in half for 4-ea. 36” legs). on the joints, (I like the foaming “Gorilla glue” type).

--One 8ft. 1x4” board, (cut into 24” sections for You can use standard "fluted Drywall” screws, they crossbeams) work well for most projects, (except treated lumber, the chemicals corrode them). Coated “Deck screws” --Two heavy-duty door hinges, (they usually come work great, but they are slightly more expensive. with screws and you can buy them in pairs).

-- A box of Screws, 1¼” wood-screws will do nicely.

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1. 1x4's cut to 36" for the legs. you will need 4ea. per sawhorse. I'm making 2 of these, so there are 8 of them here. 2. Wood! 1x4" at 24" long, you could also use 1x6" if you wanted them sturdier, (these are at 48" for a specific project)

Folding Sawhorses, Simple and Handy!: Page 6 Step 4: Cutting and Basic Pre-assembly

As I mentioned, I usually like to build these two at a -Apply a little glue to the joint and secure with 1- time. It really doesn’t take much more effort, (the tools screw at each corner joint, (so it can move a bit). it is are already out), and these are really very handy in a good idea to stay near the lower edge of the top- pairs. beam, we will be putting hinge screws up there later.

-measure halfway down the “leg” (about 18”), glue -For each sawhorse; that joint too, then install 1-screw.

--Cut the 2ea. 6’ boards at half-length, (or 36”), so you -Check for square, (use the framing square for this), have 4ea. “legs” -Cut the 8’ board down to 2’ lengths, only then should you install a SECOND screw in so you have 4ea. Beams. each joint.

-Set the top beams on the legs at right angles to the Repeat the process for the other side, (or sides if you legs, (a speed square is great for this). I like to do this are making multiple units). on the garage floor, but any suitable flat surface will do

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1. Tech tip; do NOT try to take pictures while using a saw! (this is after the 1. All laid out ready for Glue-n-Screw! cutting).

Folding Sawhorses, Simple and Handy!: Page 7 1 1

1. Add a little glue on the lap-joint at the corners. You don't need much, (it 1. Remember, add only ONE screw in each corner joint, until you have tends to squeeze out when you add screws). them ALL squared up!

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1. Line up the boards so they are sort-of square.

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1. Also be carful about getting too 1. It's also a good thing if you avoid putting screws in places that you need to put OTHER Screws. like where your close to the end of boards, they hinge is going to be. Which is right here. tend to split.

Step 5: Put Them Together.

-Place two completer sides on the floor with the top that you want them to be. beams on the bottom, and butted-up and against each other. I like to use a clamp at this point, but you Insert a cord through the holes and adjust the length could just brace them against a nearby wall. until the sawhorse sits about as high as you want it, then just tie-off the cord. Remember, if you are making a pair, you are going to want cords about the -screw the hinges onto the corners, flat-side down, same length, (making them about the same height). (yes hinges have a flat-side), and straddling the seam between the sides. You could use the hardware that Don't forget to check for square. If they are just a little came with the hinge, but I just used the same screws off, don't worry, they will settle. if they seem WAY off, as in the joints, (longer and sturdier). back out your corner-joint screws a little, and put some weight on them. Then re tighten the screws - Fold the two sides over onto each other. Drill a hole under some (light) pressure. They should be fine, in the lower beams for a cord to go through. once you have satisfied yourself that they are MOSTLY straight and square. -Stand them up, and set them for about the height

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1. Top beams butted up against each other, (floors are handy for this part). 1. I cheated and used a clamp, but you could just push it up against a nearby wall, or cinder block, whatever you have.

Folding Sawhorses, Simple and Handy!: Page 11 1

1. Yup, Hinges have a flat-side. Put that side against the wood.

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1. I like to put ONE screw in each side to check everything out before committing myself.

Folding Sawhorses, Simple and Handy!: Page 13 Folding Sawhorses, Simple and Handy!: Page 14 1

1. Just pull the cord up to fold the sawhorse. Could NOT be easier!

Folding Sawhorses, Simple and Handy!: Page 15 Step 6: Conclusion and Notes

Now, You COULD make these heavier if you felt that projects). you needed too. Building them with “Two-By” lumber, (2x4” or 2x6”) makes them crazy-sturdy! They would I have been using this basic design for years. My still be portable, but a bit bulky to move around easily. father used them in his side-business as a Trim- You would need correspondingly longer screws, ( 2 Carpenter and general handyman. He got really good ¼” - 2 ½”), but the build process would basically at being mobile, because he usually worked out of an remain the same. old jeep. These folding sawhorses were a mainstay of his operation, and he usually had at least one with I actually have an old pair made with leftover decking him on every job. boards and galvanized hardware. They’ve been sitting outside for a few years now, without any I hope this helps someone out there, Enjoy and good issues. They are currently holding up a big pile of luck! “fence and barn” wood, (weathering for future

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1. This is why the hinge doesn't mar the project.

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1. Yup, they fold up flat! 1. Did I mention "sturdy" this is a load of 2x4s and 2x3 studs for another project. And these are made with 1x4's

Nice. I need some of these from my shop.

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