Sawhorse Jig

Description

This is a jig to make a sawhorse (actually to make infinite sawhorses). It’s handy as hell and you need sawhorses (you can never have too many sawhorses). It’s a good beginner project because sawhorses aren’t rocket science but they’re stupidly overpriced at your local box store.

This is a sawhorse I made. I’m not some Roy Underhill / Bob Vila woodworking pro. I can barely chew gum and walk at the same time. Yet look at the sawhorse I made. It’s perfect.

Don’t go overboard. If you’re messing with chisels and Japanese pull saws you’re overthinking it. You don’t need anything but basic tools and basic skills.

You save money too. Each sawhorse you build will cost about half what the store charges.

Your sawhorse will be better than the store versions. You know why? Because it’ll be 100% wood instead of the plastic crap they’re slinging at the store.

Having a jig turns the job from easy but math-y* to a complete breeze! (*I’ve decided “math-y” is a word.)

Here’s the jig hanging on my shop wall. It’s been used a bunch of times. It’s the key to infinite sawhorse awesomeness.

If you want, you can figure it out for yourself. Remember high school geometry? The square of the sides something something hypotenuse right triangle, carry the one… zzzzzz… Did you fall asleep? Don’t worry. Remember when your teacher said you’d need all that? He was wrong. High school is over. Buy a jig and just cut the lengths and angles it says.

The lengths of pieces are embedded into the jig itself. It’s not a sticker or stenciled on so you’re not going to scratch it off. Nor will you forget a set of measurements you jotted on scrap paper.

Not only are the measurements embedded in the jig, so are the angles. Just trace some lines with a pencil, cut up three (3!) two by fours, and screw the whole thing together.

Here’s one angle, used on the leg spreader. It’s just traced from the jig.

Here’s the other angle, used for the top of the legs. The jig slides over the two by four so you can trace it on all four sides.

Here’s the angle cut for four legs.

Go for it! A sawhorse jig hanging on the wall says “this guy knows what he’s doing”. Projects made on your own solid wood sawhorses are always better. Become 100% self sufficient in sawhorses for life! You’ll impress men, attract women, lose weight, have better hair, get better MPG, and your chainsaw will always start on the first pull.*

(*OK maybe not, but it could happen.)