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Strong, Durable, Collapsible, and Versatile: How to Build a Better Sawhorse
Posted By A Manly Guest Contributor On August 16, 2012 @ 1:55 pm In Manly Skills,Projects,Toolmanship | 25 Comments
As I continue to expand my workshop, I quickly discovered the need for some good sawhorses. Sawhorses are great for setting up a temporary workspace, out-feed (on my table saw), and more. Now you can slap some sawhorses together pretty quickly and they’ll work just fine; Brett shared a fast and easy sawhorse design  awhile back if you’re looking for something nice and simple. But I didn’t want to compromise on features. So I scoured the internet for ideas, and eventually decided on this design called the Shopdog. 
These are not the easiest sawhorses to build. However, they are extremely strong, durable, collapsible and versatile. The versatility comes from the fact that the cross member can be modified depending on the application. For instance, cutting V notches into the top makes it easy to support round pipe. Stapling carpet over the top is perfect for protecting woodworking projects. Best of all, if the cross member gets messed up, all you have to do is swap in a new piece of 2×4. I’m confident that you won’t find a better workshop sawhorse anywhere else. Now here’s how to build ‘em.
These are the tools and materials I used to build the sawhorses. The total cost for each sawhorse is less than $20, and a big chunk of that is for the locking tie-down. If you can find a suitable alternative, I’ll bet you can get the price tag under $15 which is cheaper than most of what you’ll find at the Big Box stores!
The Shopping List
To keep these instructions as clear as possible, I’ve labeled a couple of pictures and listed the necessary cuts. Remember that you’ll need to cut miter and bevel angles on the top and bottom of each piece while maintaining a consistent length. All my legs measure 40″ long, but you can change that to whatever length you prefer.
The cuts I list below assume the work piece is on the right-hand side of the miter saw, same-side up.
The cross-member needs to sit parallel to the ground (for optimal support), and that requires making a compound cut to notch each leg. Unfortunately, you can’t complete the notch with just a miter saw, and here’s where the jigsaw come into play. If you’re looking closely, you’ll notice the cross member sits proud (higher than the legs) and this is because that little extra space helps protect the legs from saw blades.
Notch all four legs on their inside edge using the same technique.
I’ve been using these sawhorses since January, and I love ‘em! Like I said, they’re not the easiest to build, but they’re worth it.
Ethan Hagan is the primary editor at One Project Closer.  Ethan spends most of his days shadowing real contractors on actual job sites and most of his nights writing about the experience. To see what I mean, check out their expert guides like How to Build a Shed Ramp  and How to Solder Copper Pipe . If learning and interacting with pro contractors sounds like something you’d enjoy, sign up for OPC email updates .
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URL to article: http://www.artofmanliness.com/2012/08/16/strong-durable-collapsible-and-versatile-how-to-build-a-better-sawhorse/
URLs in this post:
 One Project Closer: http://www.oneprojectcloser.com/
 repairing drywall: http://www.artofmanliness.com/2012/05/01/how-to-patch-a-hole-in-your-drywall/
 building a workbench: http://www.artofmanliness.com/2012/04/04/how-to-make-a-work-bench/
 a fast and easy sawhorse design: http://www.artofmanliness.com/2011/09/15/how-to-build-a-quick-and-easy-sawhorse/
 Shopdog.: http://lumberjocks.com/projects/16736
 How to Build a Shed Ramp: http://www.oneprojectcloser.com/how-to-build-a-shed-ramp/
 How to Solder Copper Pipe: http://www.oneprojectcloser.com/video-how-to-solder-copper-pipe/
 email updates: http://feedburner.google.com/fb/a/mailverify?uri=OneProjectCloser&loc=en_US
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