This project is by Craftswright. Building a folding sawhorse is not only budget-friendly but also adds a practical tool to your workshop.
In this tutorial, we will guide you through the steps to create your own sawhorse that is versatile, strong, and easy to build.
Step 1: Understanding the Need for a Sawhorse
There will come a time when you need a temporary solution to lift your work off the ground to a workable height. Whether you’re painting cabinets, setting up for a garage sale, or working on a job site, having a stable surface is crucial. The answer to this problem is a sawhorse.
While it might be tempting to purchase a fancy metal sawhorse from a big box store, you miss out on valuable skills by doing so. Moreover, these metal sawhorses can be heavy and clunky, making them inconvenient for many tasks. Instead, building your own wooden sawhorses can save you money and provide a better experience.
Step 2: Defining Your Requirements
Before you start building, it’s important to outline what you want from your sawhorse. Here’s a checklist of features to consider:
- Budget-Friendly: You don’t want to break the bank while building these.
- Strength: The sawhorses must be sturdy and able to handle weight without bending.
- Repairable: In case of accidental damage, it should be easy to fix.
- Modular: Aim for versatility so that one tool can serve multiple purposes.
With these features in mind, you can create a design that meets your needs while being functional and practical.
Step 3: Choosing the Right Design
There are various designs for sawhorses, but you want one that is foldable, strong, and easy to build. A popular choice is the half-sheet of plywood style, which folds up nicely and is easy to store. However, consider the cost of materials, as plywood can be expensive.
Two-by-fours are a more economical option. They are generally inexpensive and can be stacked to save space. However, they may need additional bracing to prevent racking, which is lateral movement that can destabilize the sawhorse.
Step 4: Gathering Your Materials
To build your sawhorse, you will need the following materials:
- Two-by-fours for the frame
- Wood screws or bolts
- Rope for lashing
- Wood glue (optional for added strength)
Gather your tools as well, which should include a saw, a drill, and measuring tape. Having everything ready beforehand will make the building process smoother.
Step 5: Cutting the Wood
Begin by cutting your wood to the required lengths. The legs of the sawhorse will need compound miters, which means they need to be cut at angles. Use two bevel gauges to mark the angles accurately. You will need a 10-degree and a 22.5-degree cut.
Once you have marked the angles, make your cuts carefully. It’s important to take your time to ensure precision, as this will affect the stability of your sawhorse.
Step 6: Assembling the Legs
With your legs cut, it’s time to assemble them. Use a carriage bolt and washers to attach the legs together, allowing them to pivot. This is crucial for the foldable design, as it allows the legs to collapse when not in use.
Make sure to tighten the bolts well, ensuring that the legs are secure but can still move freely. If your dimensions are correct, the legs should open up without obstruction.
Step 7: Adding Cross Members
Next, you will need to add cross members to your sawhorse for added stability. These cross members should be positioned alternately on the legs, ensuring they fit snugly and prevent any racking.
It’s important to measure precisely when attaching these cross members. They should be spaced correctly to avoid any wobbling or instability when weight is applied.
Step 8: Lashing the Cross Members
To ensure the cross members stay in place, you will need to lash them together using rope. Start by cutting a piece of rope about 10 feet long. Use a bowline knot to create a secure loop around one end of the cross member.
Next, create a trucker’s hitch to tighten the rope and secure the cross member. This knot is not only strong but also easy to release when you’re done using the sawhorse.
Step 9: Testing Stability
Once your sawhorse is fully assembled, it’s time to test its stability. Ensure that it can hold weight effectively without collapsing. This step is crucial for ensuring safety when using the sawhorse for various projects.
While you may be tempted to test the limits of your new sawhorse, remember that it is designed for functionality rather than extreme strength tests. If it can hold your typical work materials securely, you’ve done a great job!
Step 10: Enjoy Your New Sawhorse!
Congratulations! You have successfully built your own folding sawhorse. This tool will serve you well in various projects, providing a reliable surface for cutting, painting, or displaying items.
Not only have you saved money, but you’ve also gained valuable woodworking skills. If you enjoyed this project, consider sharing your experience and the final result with others. Happy woodworking!