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.

2 comments

  1. Informative article about How to Make the Best Saw Horse. I am looking this kind of educational article last few days. I am really glad about your article post. I don’t how can make the saw horse. But now I am clear my all confusion. Simply the best article. Loved it.

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