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How to make a Sawhorse

Step 7: Fix the legs to the beam

attach the legs to the sawhorse top

Place the top of a leg into the rebate in the beam. (See far left picture above.)

Apply glue and align the top of the leg so that its innermost point is flush with the beam top.

Then nail it in place with three galvanized flat-head nails 2 1/2" (60mm) long.

Do the same for the other three legs.

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Step 8: Brace the legs and trim the top of the legs

brace the sawhorse legs

Cut two braces from (18mm) thick plywood or board 6" (150mm) wide.

Make the top of the two braces 7 3/8" (190mm) long.

Mark the sides running out 20° off square, then cut. (fig.1)

Fit each brace to the top of the legs hard up to the underside of the beam. (fig.2)

Fix the braces to the legs with glue and three galvanized flat-head nails 2 1/2" (60mm) long each side.

Finally, lay the sawhorse on its side and cut off any leg bits that protrude past the top of the sawhorse. (fig.3)

There, done!

the sawhorse is finished

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