How to Build a Classic Sawhorse
Here’s a classic sawhorse that’ll take a ton of punishment with nary a wobble. The key is a boxlike construction where the legs join with the top board. For each one you make, you need:
- 1 42-in. long 2×6 for the top board
- 4 28-in. long 1×8 boards for the legs
- 4 8-3/4 in. x 7-in. x 3/4-in. thick boards for the gussets
- 2-in. drywall screws
Cut the gussets with 14-degree angled sides. Cut leg notches on the top board 6 in. from the ends and with 14-degree angled sides so the legs will cant outward when screwed on. Cut 14-degree angles on both ends of the legs with your circular saw’s table set at 14 degrees. Cut the taper along the inside edge of the legs, and loosely screw the legs in the notches. Now, screw and glue the gussets to the edges of the legs. Because you haven’t tightened the legs in the notches, they’re easy to line up with the gussets. After attaching the gussets, tighten the screws that hold the legs to the top board, and you’re done.
Thanks to reader Ernie Brown for this thoroughbred tip.
Comfortable Shop Apron
The string of a light-duty shop apron can really slice into your neck when you load up the apron with screws and tools. Resourceful reader Steve Dailey advises: Replace the neck and waist strings with heavy-duty suspenders ($5 at home centers). Once you adjust the suspenders, they do a great job of comfortably distributing the load.
Homemade Edge Banding
If you’re building a project from ﬁr plywood and you need edge banding that’s an exact match, check out Sue Barlow’s revolutionary idea. On a table saw, cut 7/8-in. wide strips of the same ply-wood you’re using for the project. Then rotate the strip 90 degrees and slice off a 1/8-in. thick strip for the edge banding. This tip lets you be creative—you can cut off long grain strips to match the wood surface, and then cut strips with cross grain to create a “fold-over” effect on the other two edges of the plywood. Caution! Use a hold-down stick and a push stick when sawing narrow pieces on the table saw. Note: This tip doesn’t work well with hardwood plywood; the hardwood veneer is too thin.