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How to make a Sawhorse
wood workers sawhorse
woodworking projects from the do-it-yourself carpentery workshop

How to build a Sawhorse Video  |  Español
bullet Page one: Introduction - Plans - Materials list
bullet Page two: The angles and the legs
arrow Page three: The sawhorse top
bullet Page four: Final assembly and braces   -   User Comments/Photos

prepare the sawhorse top Step 5: Mark the sawhorse top for rebating

You will need to make four rebates (check-outs, notches) in the sawhorse top to house the tops of the legs.

Refer the pictures on the right to help clarify the instructions.

Measure 5"(125mm) in from each end a to point b and then mark a 14° bevel line across the edge. See fig.1.

Do the same to both ends of both sides (four in all).

Next mark the width of the 'cut-out' area which will be the same width as a leg.

Use a leg as a template. Hold a leg against one of the bevel lines at point b and with a pencil, mark along the opposite edge of the leg. See fig.2.

Mark the 'cut-out' depth which will be 3/4" (20mm). See fig.3.

rebate the sawhorse top to take the legs Step 6: Rebate the top to house the legs

Make multiple saw cuts across the 'cut-out' area down to the marked cutting depth which is 3/4" (20mm).

Three or four cuts across each cutting area should be enough for straight grain wood, but if the wood is a bit knotty then make more cuts.

The more cuts you do, the easier it will be to chisel out the rebate.

Next lay the sawhorse top on its flat end and commence chiseling along the depth line.
Do not go too deep initially.
Chisel in a little bit one side, then turn the sawhorse top over and chisel in a little bit on the other side. Turn the top over again and chisel a bit deeper and so on and so on, until the chips of wood fall out and the 'cut-out' area is clean.

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