As y’all know I’ve been selling sawhorse jigs and rigs at https://adaptivecurmudgeon.com/sawhorses/.
What you don’t know is I tossed in a little half page printed document. I considered it sort of a “value added” thing. In private responses everyone seemed to like it. One person who ordered some jigs asked that I post the document so he could include it as he distributed jigs as gifts. That’s a reasonable request and I’m happy to comply. I’m pasting it below:
How to make a sawhorse (instructions for beginners)
- Take a deep breath. Relax. Does this help make a sawhorse? Not specifically. Do it anyway.
- Buy three studs. A “stud” is a piece of wood that’s 96” (eight feet) long. It’s called a “two by four” and is 1½” by 3½”. Why are the name and the dimensions different? Don’t ask.
- Select the straightest “studs” you can find. Pick the best of the bent spaghetti the store is selling. Buy an extra stud. You won’t need it unless you screw up but lets be real.
- Also buy a box of 3” Torx screws. As a test of stoic prowess, try to buy absolutely nothing else.
- Optionally: on YouTube look for Perkins Builder Brothers. Watch Building The Perfect Job-site Sawhorses. All hail irreducible complexity! Like & subscribe. Now turn your phone off. (Link)
- Follow safety precautions. Ear & eye protection, etc… Don’t be stupid around power tools.
- Cut the straight cuts as listed on the jig. Everything but the leg spreader. You will use every inch of your materials. Measure twice and cut once. Keep your phone off.
- Use the jig to trace the angle at the top of all four legs. Trace with a pencil and put the jig away; possibly in another time zone. Don’t try to hold the jig in place while cutting. I shouldn’t have to say that, but I do. (If you bought “fancy feet” trace the angle on the bottom.)
- Cut along the lines. I like to use a bandsaw. You can use what you want. Be safe.
- On one 48” piece, make pencil marks 1” in from the ends. That’s where the legs go.
- On the legs make pencil marks 12 1/8” from the bottom (do this before you cut fancy feet). That’s where the leg spreader goes.
- Hey, did you turn your phone back on? I told you to leave it off. You need a break from it.
- Use the jig to trace the angle for the leg spreader. If you make straight cuts and then cut the angle you’ll run low on wood. Once you’re done, make pencil marks ¾” left and right off the center line. That’s where the 41” piece goes.
- Assemble your sawhorse. If you’ve got a nail gun, use a few finish nails to tack it in shape.
- If you don’t have a nail gun, don’t use a nail gun.
- If you want to drill pilot holes for your Torx screws, do so. If you don’t want to, don’t.
- Tighten it all up. Checking that everything is straight and true before you crank it tight.
- You’re done. Is the phone still off? Good. Relax a few minutes before you turn it back on.