Adjustable Saw Horses

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A good sawhorse is something essential in a workshop, especially if you workwith wood and you often need to take outside some board or piece to cut andsand.

And if you need a temporary table in the garden for barbecue and parties, thesetwo stacking and adjustable sawhorses are the perfect support.

(http://cdn.instructables.com/F21/XJZL/IC5C1QC9/F21XJZLIC5C1QC9.LARGE.jpg)About This Instructable

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(/member/andrea+biffi/)

andrea biffi (/member/andrea+biffi/)www.andreabiffi.com(http://www.andreabiffi.com)

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I'm an Italian freelance structuralengineer, graphic designer and

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1 of 17 27/07/15 08:57

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Step 1: The project

I built these stands for the woodworking workshop where I use to take part. Ifound some wood boards and I adapted my project to their dimension and

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photographer. I'm also investigatingelectronics, robotics and science ingeneral. I enjoy hacking and disassemblingas much as desig...read more » (/member/andrea+biffi/)

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Adjustable wood sawhorse http://www.instructables.com/id/adjustable-woo...

2 of 17 27/07/15 08:57

length. I wished a very stable, solid, and tall sawhorses pair, so that everybodycould work standing right in front of the temporary table.

I inspired to a nice couple of sawhorses by IKEA (https://www.google.com/search?q=ikea+finnvard&hl=it&biw=1920&bih=1041&site=webhp&source=lnms&tbm=isch&sa=X&ved=0CAYQ_AUoAWoVChMIxuXD-9DhxgIVqgjbCh11PQ_E), as you can see in the image. But I build them biggerand stronger, with the stacking feature too.

You can see a drawing with actual dimensions.

Step 2: Material and cutting

(http://cdn.instructables.com/FRV/0D2P/IC5C1QCA/FRV0D2PIC5C1QCA.LARGE.jpg)



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3 of 17 27/07/15 08:57

Find good and straight wood boards, I had 70x45mm section for main horizontalelements, but your can be different.

Tilt the table saw at an angle of 15° and cut lengthwise those elements, as in theproject. Then complete the cut with another (this time vertical) lengthwise cut.Keep all the pieces you obtain with these cuts.

Also cut all the boards at the right length. Keep in mind that all angles for thisproject are 15°, and that the feet need to be cut with double grade, both for thelonger and the shorter side.

Always check that there are no nails in the boards before sewing.

Step 3: Gluing

(http://cdn.instructables.com/FO1/RST0/IC5C1QCB/FO1RST0IC5C1QCB.LARGE.jpg)



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4 of 17 27/07/15 08:57

When you have all the pieces assemble them on a flat table, use some woodglue and clamps. Check that space between small blocks are enough to let thevertical boards stay between.

I suggest to cut some small wood wedges with 15° side, so that you will have aright surface to use the clamps.

Step 4: More gluing

(http://cdn.instructables.com/FWM/P39D/IC5C1QCC/FWMP39DIC5C1QCC.LARGE.jpg)

(http://cdn.instructables.com/FMT/7NS0/IC5C1QCE/FMT7NS0IC5C1QCE.LARGE.jpg)



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5 of 17 27/07/15 08:57

Go on gluing paying attention to all angles and dimensions. You can adjustpieces position for some minutes after the assembling. You can also use somecords.

I didn't have used wood dowels for now. I think it's simpler, but you have to bevery careful to not move the pieces mutually after ten minutes, and you have tokeep them very tight together.

Step 5: Clamps

(http://cdn.instructables.com/F6K/2JJB/IC5C1QCS/F6K2JJBIC5C1QCS.LARGE.jpg)

(http://cdn.instructables.com/F1O/83HS/IC5C1QCT/F1O83HSIC5C1QCT.LARGE.jpg)

(http://cdn.instructables.com/FU0/NP2G/IC5C1QDX/FU0NP2GIC5C1QDX.LARGE.jpg)



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6 of 17 27/07/15 08:57

It's better you use long clamps if you can, and if you have enough. I used somebike tubes too.

Step 6: Drying

(http://cdn.instructables.com/F2L/AN8V/IC5C1QDO/F2LAN8VIC5C1QDO.LARGE.jpg)

(http://cdn.instructables.com/FAS/PQY6/IC5C1QD1/FASPQY6IC5C1QD1.LARGE.jpg)



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7 of 17 27/07/15 08:57

Let the glue dry at least a few hours. But read instructions on the glue and followthem.

Step 7: Drilling

(http://cdn.instructables.com/FU7/P934/IC5C1QCV/FU7P934IC5C1QCV.LARGE.jpg)

(http://cdn.instructables.com/FI2/RPZT/IC5C1QE9/FI2RPZTIC5C1QE9.LARGE.jpg)



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8 of 17 27/07/15 08:57

When glue is completely dry you can remove clamps and starting drilling holesfor dowels.

You don't have to be 100% accurate to determine position of the holes, just besure that depth is the same value of the dowels length.

Also remember that you need at least two dowels for each connection, betterthree not aligned. If you can try to not exit at the opposite side, so that it will besimpler adding glue in the hole. For some connections you see that I drilled two

(http://cdn.instructables.com/FGG/63SR/IC5C1QEO/FGG63SRIC5C1QEO.LARGE.jpg)

(http://cdn.instructables.com/F5W/RLYS/IC5C1QEQ/F5WRLYSIC5C1QEQ.LARGE.jpg)



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9 of 17 27/07/15 08:57

holes on one side and an hole on the opposite side, so that I will insert threedowels.

Step 8: Adding dowels

When you have all the holes drilled, you can add glue and insert dowels. Usuallydowels can protrude out the surface, so that you will refine them with a saw afterglue drying.

(http://cdn.instructables.com/FVP/D73A/IC5C1QCP/FVPD73AIC5C1QCP.LARGE.jpg)

(http://cdn.instructables.com/FX1/LOMZ/IC5C1QEV/FX1LOMZIC5C1QEV.LARGE.jpg)



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10 of 17 27/07/15 08:57

Step 9: Adjustable part

Time to make the top part of the sawhorses, the part which you can raise andlower to have different heights.

Since I had wood cylinders with 20mm diameter, I chose to make 20mm holes.Always check what material you have before going on with the project.

Make some test to decide the distance between holes in the vertical beam, Idecided to make 5 holes at 50mm distance. Leave at least 80mm under thelower hole.

Step 10: Place and glue

(http://cdn.instructables.com/F73/TH8G/IC5C1QCJ/F73TH8GIC5C1QCJ.LARGE.jpg)

(http://cdn.instructables.com/FQJ/GLAQ/IC5C1QCO/FQJGLAQIC5C1QCO.LARGE.jpg)

(http://cdn.instructables.com/FDW/90NA/IC5C1QCM/FDW90NAIC5C1QCM.LARGE.jpg)



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11 of 17 27/07/15 08:57

Now place the vertical elements in the rectangular holes of the lower part. Payattention that at last I decided to place vertical elements not symmetrically to thecenter of the sawhorse, so that sawhorses will be stackable.

If beams enter with some difficult you have to enlarge holes with chisels, justpay attention to not exaggerate.

You can place with glue and clamps the horizontal boards alongside the verticalelements. Again check all perpendicularity and distances.

Step 11: Add dowels

(http://cdn.instructables.com/F9C/4WOY/IC5C1QEW/F9C4WOYIC5C1QEW.LARGE.jpg)

(http://cdn.instructables.com/FBJ/40FE/IC5C1QEX/FBJ40FEIC5C1QEX.LARGE.jpg)



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12 of 17 27/07/15 08:57

Also for these parts you have now to drill holes and glue dowels. Use twodowels for each connection. Let it dry for some hours.

Step 12: Refine dowels

(http://cdn.instructables.com/FYR/SM5Z/IC5C1QF9/FYRSM5ZIC5C1QF9.LARGE.jpg)

(http://cdn.instructables.com/F71/E6TX/IC5C1QFC/F71E6TXIC5C1QFC.LARGE.jpg)



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13 of 17 27/07/15 08:57

When all dowels are glued and the glue is dry, you can take a Japanese saw(https://www.google.com/search?q=buzz+saw&espv=2&biw=1920&bih=1085&tbm=isch&tbo=u&source=univ&sa=X&ved=0CDMQsARqFQoTCIjY1O-U-MYCFQEbFAodDfgJug#tbm=isch&q=japanese+saw) and cut the outer part ofthe dowels.

Step 13: Stacking feat

(http://cdn.instructables.com/F7V/4V7D/IC5C1QF7/F7V4V7DIC5C1QF7.LARGE.jpg)

(http://cdn.instructables.com/FL2/TB4P/IC5C1QF6/FL2TB4PIC5C1QF6.LARGE.jpg)



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14 of 17 27/07/15 08:57

To help staking the two sawhorses, I cut with chisels in one sawhorse the partcorresponding to the vertical elements of the other one. Refine the cuts with afile.

You can also paint one or both of them as you wish.

(http://cdn.instructables.com/FYG/YBSC/IC5C1QGF/FYGYBSCIC5C1QGF.LARGE.jpg)

(http://cdn.instructables.com/F1P/6G2E/IC5C1QGG/F1P6G2EIC5C1QGG.LARGE.jpg)



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15 of 17 27/07/15 08:57

We have a Please be positive and constructive.

Add Images Make Comment

Step 14: Test and enjoy

The sawhorses are completed now and you can test their stability and solidity.One of them can keep with no difficulty my 80 Kilos of weight. You will use themfor years.

seamster (/member/seamster/)

I like the clean and sleek design; very nicely done!

(http://cdn.instructables.com/FJ4/CJ0T/IC5C1QHL/FJ4CJ0TIC5C1QHL.LARGE.jpg)

(http://cdn.instructables.com/F82/59C5/IC5C1QHK/F8259C5IC5C1QHK.LARGE.jpg)

(http://cdn.instructables.com/FJL/E16P/IC5C1QIR/FJLE16PIC5C1QIR.LARGE.jpg)



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16 of 17 27/07/15 08:57

Adjustable Saw Horses

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