How to Make a Great, Sturdy Sawhorse to use for just about Anything

• Materials needs:

2-2x4s (12 feet long)
1-2x6 (8 feet long)
1-2x2 (4 feet long)
1-20x48 inch pieces of 3/4 inch plywood
124 deck screws (2 inches long)
8 deck screws (3-1/2 inches long)
8 deck screws (4-1/2 inches long)

Be sure and use good-grade lumber, for your sawhorse to be sturdy.

• How to construct:

1. Make a 10 inch mark from the corner of one leg of a right angel. One the other leg, make a mark 24-1/2 inches and another 30 inches from the corner. At the 30 inch mark, draw a line perpendicular to the leg itself.

2. Position a 2x4 with one corner on the 10 inch mark and the opposite edge aligned with the 24-1/2 inch mark. Draw a line on the 2x4 with a straight edge or a carpenter's square.

3. Use the same straight edge or carpenters square and draw lines positions with one side directly above the vertical edge of the right angle at the 30 inches mark and the other die directly above the line drawn perpendicular to that side of the right angle.

4. The 2x4 is now marked and ready to be cut. Using the dimensions in these instructions, the angle at the bottom and the top of the leg is 75 degrees, but this angle will change with other dimension. Repeat steps 2 through 4 to create the remaining seven legs.

5. Position the leg at the end of the 2x6 beam, it should be 40 inches long, and drive a 4-1/2 inch screw through the leg into the beam 1-1/2 inches from the top.

6. Turn the sawhorse over and drive a 3-1/2 inch screw through the beam and into the leg 3/4 of an inch up from the bottom of the beams.

7. Turn the sawhorse again and remove the 1st screw and pivot the leg and the remaining screw until the leg is parallel to the beam. Position a second leg, opposite the first, and drive 2 3-1/2 inch screws through the beam and into the 2nd leg. Locate one screw next to the horizontal leg and the other about 2-inches below the top edge of the beam.

8. Rotate the first leg back into position and replace the screw you removed to tighten both. Repeat steps 5 through 8 for each of the 3 remaining sets of legs.

9. Position a 9-inch wide pieces of 3/4-inch plywood so that is top edge rests against the beams bottom edge and is even with the side. Drive 2-inch screws through the plywood and into each leg.

10. Mark the plywood along both outside edges of the legs. Remove the screw and saw to the lines. Using the piece as a pattern, saw three more pieces the same size.

11. Fasten the plywood to the legs with 12-2-inch screws. Draw a vertical line from each of the corners of the beam on the lower side. To make the braces; cut 8 right triangles with 10-1/2 inches legs from the 3/4 inch plywood stock. Cut four 2x2s about 9 1.2 inches long with one end square and the other end a 45 degree angle.

12. Using two 2-inch screws fasten one of the cut 2x2s between the lines drawn underneath the beams.

13. From the other side, drive three 2-inch screws through the plywood brace and into the 2x2.

14. Using a 2-inch screw, fasten the triangle piece to the beam and the 2x2.

15. Fasten a second triangle to the other side and repeat steps 11-15 with the remaining legs, beans, 2x2 and plywood braces.

And you’re done. That's it. If you need a better step by step guide, visit here.

 

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