Supercharged SawhorseComments (0)
This article is from Issue 71 of Woodcraft Magazine.
Build a pair of portable workhorses for jobs in and out of your shop
Necessity can be the mother of invention, but in my case, it’s also been the mother of a few mistakes. Over the past 20+ years, I’ve lost count of the times when I’ve struggled without a sturdy set of sawhorses. When drywall buckets and tailgates failed, I’ve settled for what I found at the home center. But flimsy, factory-made plastic horses always come up short. So I was spurred to grab the reins and aim for thoroughbred performance. With help from fellow woodworker Tom Whalley, I finally found a horse that will stand up to any project.
While most sawhorses are designed just to provide general-purpose support, these steeds have features that enable you to accomplish specific woodworking tasks, as shown here.
I assembled the frames with Titebond III and finished the legs, rails, and top with General Finishes Outdoor Oil. For extra water protection, I shoed the feet with rubberized paint (see the Buyer’s Guide on p. 64). Should a saw blade slice through the top, resaddling is a cinch. Simply remove the screws, install a replacement, and you’re back in the race.
Portability & versatility
These folding sawhorses are sturdier and steadier than store-bought plastic versions. They’re also designed with common woodworking tasks in mind—like processing full sheets of plywood, gluing up solid wood panels, and providing built-in clamping capabilities.
Hinged frames make a solid folding horse
- Select and mill stock for the rails and legs.
- Cut legs to finished length, with leg ends cut to 15° bevel.
- Rip top rails to final size, including 15° bevel along top edges.
- Dado the legs for the rails.
- Assemble the leg and rail frames.
- Install the upper hinges, then attach the shelf.
- Attach the saddle.
- Make and notch the rails for the cutting platform.
Screw on the saddle. A scrapwood drilling guide helps a 1⁄8 × 6" twist drill bit hit the rail.
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