My shop lacks space for a full-time extra worksurface. Instead a pair of plywood sawhorses play that role. This design came from ShopNotes. The idea behind it was to build a set of four sawhorses from a single sheet of plywood. The sawhorses stack stably for storage or to create a taller working surface.
Even with just two, I find these sawhorses invaluable. In my workshop, their primary purpose is for cutting down long boards with a hand saw. The shelf holds the saw, a square, pencil, and ruler. Since they're the same height, the board is less likely to pinch around the blade. I use them as a bench to sit at while working on project parts while my body serves as a clamp.
Another common use is a platform. This allows me to set up a workstation for cutting plywood with a track saw and a cutting table, as well as an assembly bench. This places a project at a just-right height with easy access all around.
They work with my regular workbench to support large assemblies or large glued up panels held in the face vise.
Additionally, their small size make them perfect for taking in the house to use as a mobile workshop for home-improvement projects. The height makes serves as a step stool for painting the ceiling or trim around a door.
Clydesdale Sawhorse
While working on a carving project, I found that my original version flexed and bounced while working with a mallet and gouges. I considered making an auxiliary top when I decided to just make a farm horse version. I call it my clydedale sawhorse. The ends are two layers of plywood instead of one. The top consists of a 2"-thick piece of oak. This sawhorse easily weighs twice the standard breed.
The video shows the major steps to build this version. There are some key details that you'll want to pay attention to. Also I made some changes with fasteners, joinery, and technque. Some just because and others suit my shop tools.
Sure this version could have taken any design. However, as handy as the orginals are, I wanted my heavyweight to play well with its stable mates. The height is the same and I made sure that another sawhorse could stack on top or be stacked.
Right now, I'm leaving the top as is. I expect the top to develop a natural patina of dings, dents, and tool marks. However, I may add some bench dog holes to register and clamp parts in place. We'll see.
Shop Update
Here at Woodsmith, we have several sets. One is in the Woodsmith Shop set. This pair is used to hold a project in process while filming.
Another two sets live in the production shop where Marc and Dillon use them for all the reasons I've already mentioned.
Build it Your Way
The simple construction of the sawhorse allows you the flexilibilty to build it depending the tools you have. The project plans assume a table saw centered workshop. However, if your shop rolls more portable power tools, you can dive right in. I think that a track saw or a circ. saw with a straightedge guide would be ideal to quickly rough out the parts.
A crucial part is to make a template for the ends. This ensures that all the ends are identical and that your sawhorses will stack.
Woodsmith's creative director Chris Fitch even converted the files to run on a CNC. This allows you to cut all the parts using a CNC router.Or just make the end template with the CNC.
Beyond the Shop
After I painted my first pair of sawhorses, the geoemtric lines stood out in a new way. So I decided that there's no reason this project couldn't find use in a home. I took a pair of the sawhorses and gave them a two-tone paint scheme. I also covered the top with cork. The result would work as a entry bench. Stretch it a little and it could be bonus seating in a living room or a side table.
For awhile, I had the pair stacked in my office where they turned into a fun shelving set for books, my coffee cup, and current magazine plans.
