How To Build a Low Sawhorse for Your Workshop


low sawhorse

Gregg Delman

.

POP Projects is a collection of new and classic projects from more than a century of Popular Mechanics. Master skills, get tool recommendations, and, most importantly, build something of your very own.


A low sawhorse sounds like an oxymoron, but you won’t believe how much you’ll use these.

Build two at a time. A plank or piece of plywood on top creates a low plat-form to set work on. If you build these out of construction lumber or 5/4 stock instead of the 1x pine that we show, they’re easily strong enough to stand on. If you make the lower shelf out of 1⁄2-inch plywood, you can shave some weight without sacrificing strength.

These Tools Will Help

Projects and Plans

The Step-by-Step

Start by crosscutting the sides using a circular saw and a 40-tooth ATBR combination blade. Choose whichever end will become the top and mark its center. Then measure and mark 1 3⁄4 inches out from the center and make a mark on the left and right. On each side of the panel, measure 11 1⁄2 inches up from the bottom, and draw diagonal lines from there to the marks at the top. This produces a cut line with a pleasing slope and space for the horizontal 1 x 4 T-brace at the top.

Now mark the triangular cutout at the bottom. Measure in 3 inches from each edge and draw a 45-degree line toward the panel center. Cut along the sloping lines with a jigsaw to the point where they intersect.



Crosscut the shelf. Use the shelf to mark the length of the vertical 1 x 4 that forms the T-support and crosscut that. Now crosscut the support cleats based on the width of the sides. The remaining pieces will be cut to length to fit the assembly.

Begin by locating the support cleats. Measure up 5 1⁄2 inches from the bottom of the sides and mark a line across the panels, then clamp a square on the line. Butt each cleat to the square and attach it with four 1 1⁄4-inch screws. Place the shelf between the two sides and clamp the three together.

Check that the sides are square to the shelf, and screw through the sides into the shelf. Remove the clamps and drive two 1 1⁄2-inch screws through the sides into the vertical part of the T-brace. Crosscut the top of the T-brace and attach with four screws.

Hold the shelf support in position, mark its length, and crosscut it. At each end, drive two 3 1⁄8-inch screws through the sides into the support and drive two screws through the shelf into it.



Source link

Leave a Reply

Your email address will not be published. Required fields are marked *