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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 3/4u 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
(2'°Ae x 40)
grooves help align pieces during assembly
NOTE: BOTTOM FLANGE BEVELED FOR LEG ATTACHMENT (SEE END VIEW)
parts made from 3a" plywood
CONSTRUCTION SUPPORTS HEAVY LOADS
NOTE: top and bottom flanges are glued to vertical piece
(3 x 40)
(2Vfe X 4O)
ShopNotes No. 93