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Building A Pair Of Heavy Duty Saw Horses
By Dave Markel, Fri Dec 9th
This pair of heavy duty saw horses is stable, sturdy and ableto hold far more then most people will subject them to. Builtfrom two by material, these saw horses will last a lifetime. Start out by measuring and cutting all your stock according tothe cutting list and set it aside. Take the legs and mark outthe tapers. The taper starts 20" up from the bottom. The legtapers to 3-1/2" at the bottom. Repeat for all the legs and cutout. The legs join the main stretchers at 75°. This cut is best madewith a circular saw. Mark your lines, clamp the stock on edgeand cut. Flip the stock over to the other edge and make thethrough cut.
Time for some assembly. On the main stretcher mark a line 1-1/2"from each end. This is the outer face of the leg. Now make asecond mark in from one edge 1". This is the top of the leg. Dothis for each leg on both stretchers. Apply some glue to the angled side of the leg and position onthe marks
you just made on the stretcher. Secure with 4 - 2"screws. Repeat for all the legs. Position the 3/8" plywood braces on the outside face of the legsbutting into the the bottom face of the main stretcher. Scribethe angle onto the braces with your pencil and cut. Apply someglue to the outside of the legs and secure the braces with 6screws, three into each leg. Now draw 2 lines down the length of each top step, offset 3/4"from center. Countersink 5 holes, 3/4" deep in each step.Alternate the holes on each side of center. Position the toponto the stretcher flush with the ends. Secure with screws only. Finally secure the lower step midway up the leg using screws &adhesive. That's all there is to it. These saw horses will easily take theload of a lift of plywood or studs. Plus the make a greatscaffold. Space about 8' apart and secure a 2 x 10 between them. About the author:Dave Markel has helped hundreds of individuals improve theirwood working skills. Visit his site at Willowbank Wood WorkingPlans
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