This pair of heavy duty saw horses is stable, sturdy and able to hold far more then most people will subject them to. Built from two by material, these saw horses will last a lifetime.
Material you will need:
- 4 @ 2" x 6" x 10'
- 4 @ 13-1/2" x 8-1/4" x 3/8"
- 2" ext. wood screws
- Exterior wood glue
Tools you will need:
- Tape Measure
- Circular saw
- Angle finder
- 8 Legs @ 2" x 6" x 28"
- 2 Stretchers @ 2" x 6" x 42"
- 2 Top steps @ 2" x 6" x 42"
- 2 Lower Steps @ 2" x 6" x 39-1/4"
Start out by measuring and cutting all your stock according to the cutting list and set it aside. Take the legs and mark out the tapers. The taper starts 20" up from the bottom. The leg tapers to 3-1/2" at the bottom. Repeat for all the legs and cut out.
The legs join the main stretchers at 75°. This cut is best made with a circular saw. Mark your lines, clamp the stock on edge and cut. Flip the stock over to the other edge and make the through 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 a second mark in from one edge 1". This is the top of the leg. Do this for each leg on both stretchers.
Apply some glue to the angled side of the leg and position on the 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 legs butting into the the bottom face of the main stretcher. Scribe the angle onto the braces with your pencil and cut. Apply some glue to the outside of the legs and secure the braces with 6 screws, 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 top onto 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 the load of a lift of plywood or studs. Plus the make a great scaffold. Space about 8' apart and secure a 2 x 10 between them.
Tips for building and maintaining your saw horses
- A moisture cured polyurethane glue works great for this project. It holds up when it is wet or frozen. This glue stand up to the elements and UV.
- Cutting the bottom of the legs level is simple. Place the saw horse on an even surface. Lay a 2 x 4 flat on the surface and scribe a line on all four sides of the leg. Carefully cut to the line with a handsaw.
The saw horses will stand secure with no wobble.
- Chamfering all the edges will help prevent splintering of the wood. The bottom of the legs should be done as well. This will prevent them from splitting when you drag the saw horse across the floor.
- Protect your saw horses from the elements with a good coat of paint or stain.
- Remember not to use glue when securing the top step. This way you can replace the top when it gets worn out.