How to make a Sawhorse
Step 1: Cut all the pieces to rough length
Cut all the pieces to the lengths given in the materials list on the previous page.
The pieces will require further cutting and the need to work with two angles: 14° and 20°.
Below explains how to get a 14° and a 20° angle.
Step 2: Getting the angles
Make an angle template by marking the required angles on a work tabletop or square panel.
To get a 20° angle, measure 1 unit across and 2 3/4 units down (as per diagram) and draw a line between those two points.
Note: A unit can be any measurement. For example: if you make each unit 4 inches, then measure four inches (1 unit) across and 11 inches (2 3/4 units) down to make a 20° angle.
To get a 14° angle, measure 1 unit across and 4 units down (as per diagram) and draw a line between those two points.
Note: Once again a unit can be anything. If your unit is four inches, it would be 4 inches (1 unit) across and 16 inches (4 units) down to make a 14° angle.
You now have two lines, one at 14° and another at 20°.
Set the bevel gauge to the required angle when needed.
Step 3: Mark and cut the top of the legs
Clamp one of the legs on its edge to a sawhorse and commence to mark the angle cut at one end the leg (the top end).
Measure 1" (25mm) across and 2 3/4" (68mm) along. (See the diagram.)
Square down from each end of the line to complete the cutting line. (See the picture.)
Cut along the cutting line with a handsaw.
Do the same to the other three legs.
Step 4: Mark and cut the bottom of the legs
Lay a pair of legs back to back on a sawhorse, i.e. in mirror fashion. (See the picture.)
Measure 25 1/2" (637mm) along the top of the legs from point a and make a mark which will be point b. See the drawing below.
From point b, use a bevel gauge to mark a 20° cut line inwards across the edge of both pieces, and to mark a 14° cut line inwards across the face of both pieces.
Then clamp one of the pieces to a sawhorse and cut along the lines with a handsaw. See picture.
The cut is a 'compound angle cut' which means that you are cutting an angle cut across the width as well as an angle cut through the thickness of the wood.
Do all four legs the same.