How to Make the Best Saw Horse

How to Make the Best Saw Horse

I will be making a fairly large live edge desktop in the near future. To prepare for this daunting task I decided to build two sturdy saw horses to support the wood slab while I work. All you’ll need to make these saw horses for yourself is five 2″ x 4″ x 8′ studs and some 3/4″ plywood. The following instructions mostly explain how to make one saw horse. The table saw was used for most of the grunt work but an inventive woodworker can easily find their own method.

To make the two top supports I cut a two by four in half. Each top support requires four notches, 3 1/2″ wide to support the legs, cut at 18 1/2 degrees. To cut the notches I built a dado sled for the table saw.

How to Make a Sawhorse

As seen in the image above, I placed two scraps of wood in the miter slots of the table saw and clamped them to a scrap piece of plywood (1). The plywood was flipped and I added more clamps to hold the miter slot wood in place while they were tacked down with small nails (2). I turned the plywood over and placed the sled in the miter slots and cut the plywood halfway with the table saw to attain the cut line. The fence is a scrap of two by four glued at a right angle to the sled (3). I made two 18 1/2 degree wedges and placed them on the plywood flush to the fence.  Each top support was placed on the angled wedges flush to the fence and passed over the dado blades to cut the angled notches (4).

How to Make the Best Saw HorseOnce the top supports were cut I started making the legs. Two by fours were cut to 38″ (5). Then I cut an 18 1/2 degree angle on the both ends of each leg like a parallelogram (6).

3/4″ plywood was used for the Isosceles trapezoid side supports. If you’re curious the angle of of the side supports is also 18 1/2 degrees, or 71 1/2 degrees depending on how you wish to think about it. Four pilot holes are drilled in the side supports to accept screws for the legs (as seen in the first diagram). Why not some photos of the finished saw horses? Well, you’ll likely see them in a future post about that giant wood slab desk top.

Tramp Art / Folk Art Ball In Cage Woodcarving

Whittling Woodcarving Carving

Life has been busy lately but I’ve managed to knock out a quick folk art ‘ball in cage’ whittling. This piece started as a young sassafras tree I found uprooted by a storm.  I collected up all the usable sections and took them home for safe storage.

As seen in the photo, I used a pencil to draw the spiral on the wood. Using only my folding pocket knife I whittled away the waste wood, leaving a section in the center to become the trapped ball. With the three spiral supports roughed out I used my pocket knife and a small rasp to shape the ball.

Happy with the form I separated the ball from the supports. The final clean up was performed with the rasp and a drug store emery board. When I find time I’ll add some oil to pretty it up.