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I-Beam Sawhorses

I build a lot of heavy furniture and cabinets in my shop. And saw-horses are the best way to get these large projects up off the ground so I can easily work on them.

What 1 needed was a sawhorse that would be lightweight and easy to move around yet sturdy enough to hold large projects.

To ensure my sawhorses would always be up to the task, I built the ones you see above. Even though they don't look heavy-duty, they support a lot of weight.

Their strength and light weight comes from the I-beam design. As you can see in the drawings below, the top and bottom flanges of the beam are nothing more than two long pieces of plywood with a groove centered in each piece.

(The bottom flange is beveled, as shown in the End View below.) Then, a vertical center rail is glued into the grooves to complete the sturdy I-beam assembly.

The legs are ³/4^u plywood with their ends beveled and then attached to the I-beam with screws. Their angled stance provides a wide base for greater stability.

Angelo Tsarpalas Glenview, Illinois

x 1V₂" Fh WOODSCREW

BOTTOM FLANGE

(2'°Ae x 40)

grooves help align pieces during assembly

NOTE: BOTTOM FLANGE BEVELED FOR LEG ATTACHMENT (SEE END VIEW)

NOTE: all

parts made from ³a" plywood

NOTE: I-beam

CONSTRUCTION SUPPORTS HEAVY LOADS

NOTE: top and bottom flanges are glued to vertical piece

TOP FLANGE

(3 x 40)

CENTER BEAM

(2Vfe X 4O)

end view

3 -->

center beam

ShopNotes No. 93