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Traditional sawhorses

Posted by Henry in MI on March 23rd, 1999 07:51 AM
In reply to sawhorses by ed lee on March 21st, 1999 06:00 PM [Go to top of thread]

Ed, traditional sawhorses are made from stuff normally found around a building site after the job was over. To make one, start with a 2x6 x36" long and rip 15 degree angles on both edges. Then take a 2x4 and rip a 15 degree angle on it. Put the 2x4 on your angle gage of the table saw and dado out the 2x6 using the 2x4 to help hold the angle for the dado cut. Usually, 2x4's are used for the legs and, if so, make the angled dado 3-1/2" wide x 1-1/2" deep into the 2x6 four inches in from each end and in 4 places.

Now cut 2x4's into 4 pieces x 36" long with 15 degree angles on each end. Be sure these are exactly the same length. Now put them in the dado's and glue and screw.

Take any 3/4" plywood and cut 4 gusset plates to go under the 2x6 and box in the top of the 2x4's. Glue and screw them in place and you are done. You can make the legs longer or shorter to fit you and the way you work. An old associate of *** ****'s had a program showing his version, but it required a radial arm saw. If you have one, you can use it to make the dado's and legs splay out to the ends as well as the sides, but the method shown above doesn't require one. I have tried building horses with the metal brackets and ended up using more drywall screws to hold it together than I have used for drywalling a whole room.

Henry in MI

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