Y’all know I’m happiest sailing my tiny boat, running a dirtbike on remote trails, or any of a dozen stupid outdoor hobbies. But all those things are just means to an end. They boil down to seeking “adventure”.

Mostly by accident, I’ve been having an adventure right now. My simple idea of selling 3d printed sawhorse jigs has been an absolute hoot! Like all adventures, I’ve encountered a thousand details I didn’t predict. Like all adventures, I’ve dealt with them as best I can and that’s been “good enough” to keep the ball rolling. By now I’ve (more or less) got things under control; filament is present, more filament is arriving, and my printer is running damn near 24/7.

I’ve bumped into a delightful array of logistics SNAFUs and learned more about 3d modeling & design than I knew there was to learn. How awesome is that?

I plan to write all about it but it’s Thanksgiving weekend and I’ve allocated most of my time for kicking back in a comfy chair by the fire. Everyone needs a rest sometimes. (I get a break but my printer does not, it’s cranking away as I type.) In lieu of reasoned discussion, I’ll leave you with a video montage that starts with Jeremy Clarkson.

First came my oversimplified understanding of an idea:

Then the hubris that comes from not considering / knowing minor logistics / materials science details:

Then I fucked up:

But eventually I figured out some shit and got the requisite elation:

First, my “unscheduled trip” was a success and everything is fine. Second, my “emergency unsupervised overnight print” came out great. I also have filament spools coming from two suppliers using two different shipping methods. And the printer is running right now.

However, I just haven’t had time to carefully plan all my production between now and a USPS shipping “drop dead date” for getting stuff into your hands by Christmas. I’m 100% sure I can fulfill everyone who has already made a “by Christmas” order. I’m 90% sure I can take more orders and get them out by Christmas too but I don’t know how many.

Starting now, all new orders “by Christmas” will be first come first served.

Everybody who checks the box “I don’t need this for Christmas” will get their order right quick too, but they deserve a halo for letting the pressure off. If you ordered like that previously or in the future… take a deep breath of satisfaction for being so awesome.

For filament supply reasons my overnight print was a rig in translucent blue. By the time you are stuffing a turkey in the oven tomorrow I’ll have four ready to go. I haven’t had time to add blue to the form but I’ll do so tomorrow. I’ll post a photo then too. (I’ve been driving all day and I’m bushed right now.)

Have a blessed Thanksgiving. I will! I dodged a health scare earlier in the year, Mrs. Curmudgeon is happy to see me hassling suppliers and messing with spreadsheets like my old self, and I’ll have a great time flogging my 3d printer like a rented mule all holiday season! What more could a Curmudgeon want?

I’ve been having tons of fun with my ad hoc sawhorse jig/rig situation. Half the time I think “nobody will want these”. An exact opposite fraction of time I think “I should buy a second printer to handle the rush. Unleash the Curmudgeonly print farm!”

I was going to post all sorts of things & ideas but life happened. I was in the middle of… everything. I was ordering too much filament that may arrive too late. I was on hold trying to find physical filament within driving distance. I had a spreadsheet up calculating print time available between now and Christmas shipping drop dead time. Priorities changed and I dropped everything.

I wound up driving hundreds of miles in a snowstorm for completely unrelated reasons. There was black ice everywhere and I spent the night in a hotel. Not an emergency, just life being life.

Just before leaving I turned the printer loose on an 18 hour print. Maybe it’s still going? I can’t post more because I didn’t bring a laptop because I don’t own one.

Isn’t is cool how things are always interesting?

This is what the feet of my sawhorses look like:

I got no problem with that. But some folks wanted more awesomeness. They want it cut at an angle. Here’s a comparison of the two different ways a leg can end:

As many of you immediately recognized, the angle on the leg’s top will match the angle on the leg’s foot. So, if you want you can use the jig I already made. It’s a little clumsy but workable.

Here’s the dedicated “fancy foot jig” next to the “re-oriented main jig”. I like the “fancy foot” better but either one will do the job. OR you could use a protractor. OR you could just ignore the whole thing. Whatever floats your boat.

Someone requested a hanging hole on “fancy foot jig”, so I added that. They also asked if I could print in yellow as well as red. Yes I can. I added that option to the order form.

All of this is up to you. Angled feet does look cooler and theoretically it’s way superior. However, I’ve been using my sawhorses without even thinking about “feet” and I didn’t notice any issues.

The sawhorse design I picked has legs that end like any normal 2″x4″; rectangular. The sawhorse’s legs are at an angle. That means the rectangular end interfaces with the ground as if it were a point rather than a wide flat surface. I never gave it much thought.

The video suggested a point is better for “digging in” to soft surfaces like dirt (for when you use your sawhorse outdoors). I’ve been using a them on my shop’s floor (cement) and outside (dirt). I didn’t notice anything good or bad about the leg’s “untrimmed” end on any surface.

A couple folks mentioned they’d like to trim the leg. They want an angled cut so the leg’s end is parallel with the floor. Who am I to complain?

I noodled around in Fusion 360, dredged up long forgotten high school geometry, and printed out a jig that does the job. Trace it on the leg (all four) and follow the line to cut the leg’s end. Now it matches the ground.

I had to make a name for the file so I called it “fancy foot”. If you’d like a jig to trim your sawhorse’s feet parallel to the ground, “fancy foot” is precisely what you wanted.

I added “fancy foot jig” to the world’s crudest order form at https://adaptivecurmudgeon.com/sawhorses/.

“Fancy foot” is entirely optional. You can make a rockin’ sawhorse without “fancy feet”. Or you can add “fancy feet” and enjoy the added awesomeness. It’s up to you.

It’s pretty simple so I’m only asking $3.

Pics or it didn’t happen so here goes. Hold the fancy foot jig on the bottom of the leg like so.

Trace a line.

Cut on the line and now your sawhorse’s feet are flat to the floor. I used a square and some scraps to test all the angles. It works flawlessly. (Note this is scrap for testing. The leg is unusually short in this image.)

Here’s how the “build the whole sawhorse” jig and the “fancy foot jig” would fit on the same leg. (Note, the leg is unusually short, it’s just scrap I used for testing.)

Improving the sawhorse produces almost no waste; which is awesome because I’m a cheap guy. A “fancy foot” sawhorse and a “default” sawhorse both use the exact same input wood.

I want to formally apologize to my high school math teachers. I whined “when am I ever gonna’ use this”. Yet, just now I was flipping angles precisely like I was taught. If my teacher had said “many decades from now you’ll use geometry to fine tune computer models that create 3d printed jigs to fine tune homebuilt sawhorses” that would have been real helpful. On the other hand, no sane person would have guessed it.

I tested my online form carefully. It worked. Then it didn’t. Go figure.

I’ve switched to a new plan. Send me an e-mail.

Go to https://adaptivecurmudgeon.com/sawhorses/ for the form and links to how to pay.

I put the whole thing here too. Sorry about the delay.

Step 1: E-mail this form.

Replace question marks and email to ac@adaptivecurmudgeon.com

My email is: ????@????.???

My address is: 
???Street??? 
???Town???, ?State? ?Zip?

My name is: ??????????????

These are the things I want:

1 <- Flat shipping cost of $7. (Required.)

? <- Number of Jigs that are yellow. $12.50 each.
? <- Number of Jigs that are red. $12.50 each.

? <- Number of Rigs that are brown. $18.50 each.
? <- Number of Rigs that are transparent turquoise. $18.50 each.

Is this a present (indicate one option):
? <- I need it by Christmas.
? <- After Christmas is fine. Deduct $0.50 off cost!

How I'll pay for it (indicate one option):
? <- Paypal (link is below).
? <- Buy Me A Coffee (link is below).
? <- Patreon (link is below).
? <- A physical check sent to P.O. Box 133, Bagley, MN 56621.

Step 2: Pay in any of several ways.

It would be handy if the name you email with the form and matches the payment but so long as you give me enough information I’ll match ’em.

This is the link to Paypal*:

This is the link to “Buy Me A Coffee”:

This is the link to Patreon:

You can send a paper check. Crazy right? Feels as dated as the Pony Express. But snailmail still works. My super-secret lair is nowhere near the PO box but I get stuff forwarded from there.

A. Curmudgeon
PO Box 133
Bagley, MN 56621

When I built an order form for sawhorses I tested it thoroughly. So, of course, it’s not working.

I’ll fix it shortly. Sorry for the hassle.

Sawhorse jigs are for sale! I’m pleased with how they came out. I think people will like them. Christmas is coming and they’re totally useful. There’s nothing more awesome than easily making a sawhorse this cool:

The jig looks like this (the photo makes it look flat but it’s a 3d jig for a 2″x4″):

But there’s more! I was trying to convey how to make a sawhorse with no words at all. I created this:

It’s a scale model of every part of a sawhorse. Nine little mini-components that have the dimension of the component embedded in the object. I also embedded magnets so you can assemble and separate the parts over and over.

I didn’t know an English word for such a thing so I called it a “Rig”. It’s for sale at $18.50. Go to the form and order up a few. The same form works for jigs and rigs.

Shipping is a flat rate $7 no matter how many or how few you buy.

I started by printing in brown because brown = wood. Then I decided to try a different look. This one is translucent. Same price as the brown rig. Same deal on shipping.

Here’s the whole happy family of “prototypes”.
The order form is here.

I made a jig that displays everything you need to create a sawhorse AND marks the angles. I wasn’t sure if anyone was interested in buying one. Turns out they were!

They’re for sale, starting now:

I made a few improvements. There’s a hole to hang it on a hook. The hole can be used to find the center of a 2″x4″; because why not? The text on the back helps you know which side of the jig to use. (If the letters are upside down, you’re using it wrong.)

Here’s how the jig marks the taper for a leg.

Here’s how the jig marks an angle for the leg spreaders.

They cost $12.50 each. Someone already asked for one in red with black lettering so I’m offering in yellow or red. (Same price.)

I went down a rabbit hole trying to figure out postage. Finally I decided dividing ounces by zipcode multiplied by USPS form number “27B/6” was hopeless. I’m charging $7 per order. Same price for one jig or ten. That’s it. Seven bucks. (I probably underestimated, but if I did that’s on me.)

The order form is on the blog’s header or you can just go to https://adaptivecurmudgeon.com/sawhorses/.  

I’ll take payment in any of several ways or you can mail me a check.

I’ll have them shipped before Christmas.

If you have a special (or large) order, e-mail me directly at ac@adaptivecurmudgeon.com.

What are you waiting for? Click over there and crash my crude order form!

Oh yeah. I had been working on my “second invention” and that’s ready to go too. Yes, it’s already on the form. I’ll describe it in my next post.

I was fiddling around with sawhorses and made a 3d printed jig. I offered to sell copies. I wasn’t sure anyone would care. Apparently I was wrong!

A handful of people were interested. How awesome is that?

I didn’t plan ahead for that. Give me a little bit of time to sort through details. I need to go to the post office and figure out how much it costs to ship a jig (or many in the same box).

Then I’ll order some filament and post a price here on my blog. The good news is I’m way ahead of the curve. I plan to print and ship with plenty of time before Christmas. Hint hint… they’re the perfect stocking stuffer for the kind of guy who knows what a miter saw is and uses sawhorses.

In case you don’t know what I’m talking about, photos of the jig are copied below (or just scroll backwards on my blog).

Here’s the jig (it’ll be a little nicer because I’ll use more infill, the photos are of a haphazard “prototype” I made for my own use). I picked the colors at random but I like how they came out. For now, I’ll plan on yellow PLA with black PLA.

Here’s the sawhorse you make with the jig. All you need is three studs and some screws. It’s a bargain compared to buying a sawhorse.

One more note, you don’t need the jig if you don’t want it. (Though it does make things much easier.) You can make the same sawhorse by following along with this video. That’s what I did at first.

Also, the video is a pleasant watch and I recommend it. The guys in it seem pretty chill. I hope it doesn’t freak ’em out that some rando (me) is making a jig. I intend to send them a free jig if there’s an address available. I haven’t done anything yet but I will. I don’t want to make a bad impression.

A.C.

P.S. If anybody wants a different color jig, that’s do-able. I think translucent blue PETG looks cool. Or you might want pink to annoy someone with a flaky color. (The pumpkin spice of colors.) Funky colors will cost a little more but I can do it. If that’s something you’d like shoot me a request in comments (or privately at ac@adaptivecurmudgeon.com).

P.S.2. I was leading up to my next level 3d printed design in “text free communication” about the sawhorse. I had a print failure so I can’t post that just yet. Still, it’ll be cool when it’s done. I’ll post as soon as it’s ready.

P.S.3. Once I get a price, I can take payment via credit card on PayPal. If you want to order, please tell me you’re interested but wait on the payment until I set a price. OK fine, if you’re nuts and want to pay like $100, just pay now. That’s crazy but I’m not going to stop anyone from burying me in cash! 🙂

P.S.4. I’ll check U.S.P.S. box dimensions but I think I can put several jigs in the same box. Buying more than one will probably cost nothing extra for shipping!

P.S.5. If you’re in a rush, I might possibly get a few jigs out by Thanksgiving. But that’s a stretch. Filament takes a week or more to deliver. I can only print “rush jobs” with “filament I’ve got on hand”. I might run out of yellow.