Popular Post TerryMcK Posted January 7, 2015 Popular Post Report Share Posted January 7, 2015 When cutting up large sheets of material, plywood, MDF etc., it is always better to break them down at a lower level (to prevent back problems) and with a circular saw (Festool track saw or even just a circular saw with a guide). I saw the design for this a few years ago and redesigned it from memory. I didn't have much difficulty in remembering the design as it is so simple. Essentially it comprises 4 legs, 3 long sections and 3 cross members. It is possible to obtain all the parts from a single sheet of 8' x 4' x 18mm (3/4" nominal) plywood. I used external hardwood plywood as it is easily obtainable from a home centre. This will support a full sheet of 8' x 4' with no problem. I can't remember the original inspiration for this design so apologies if it was you. First of all I designed it on Sketchup and came up with this. I can also upload the Sketchup file if anybody is interested. One possible assembly As the saw horse construction is modular there are several permutations for the assembly. Here is another one. Another version of assembly The holes are simply to lighten each individual component and are 100mm (4") diameter. Dimensions. Here are the rough dimensions. They are in millimetres but it is very simple to convert to inches (divide by 25.4) and the figures are not critical. Each slot is 20mm wide and 100mm long. The slanted slots are at an angle of 75 degrees. Crossmember #1 - 2 required Crossmember #2 - 1 required Leg - 4 required Long section member - 3 required As mentioned above you can get all pieces from one sheet of 8' x 4' so here is my preferred layout Layout detail The resulting structure is surprisingly strong when assembled, very stable and can support the weight of this woodworker (especially after the Christmas excess) and is very stable. I will be using mine to break down sheet goods and also as a base for a torsion box low assembly table. I will cover the actual construction of the design later through the thread along with the torsion box table. Note that the resulting platform is only about 22" from the floor but I find it is an ideal height to lift sheets onto, use a circular saw or a panel saw. I also don't mind if I cut into the members with a saw blade. It can also pack away into a relatively small space when not required so great for shops with little floor space. Take it out onto the driveway if you want too. Feel free to use my design as I'm sure a similar design is already on the internet somewhere. 8 Quote Link to comment Share on other sites More sharing options...
wtnhighlander Posted January 7, 2015 Report Share Posted January 7, 2015 Very useful design, Terry. Thanks for posting this. Quote Link to comment Share on other sites More sharing options...
..Kev Posted January 7, 2015 Report Share Posted January 7, 2015 Pretty cool Terry! Quote Link to comment Share on other sites More sharing options...
TerryMcK Posted January 7, 2015 Author Report Share Posted January 7, 2015 Leave out the upper hole in each triangular leg. I've just thought it is too close to the upper slot and weakens the structure ( I haven't bored any holes in mine yet) 1 Quote Link to comment Share on other sites More sharing options...
Popular Post TerryMcK Posted January 9, 2015 Author Popular Post Report Share Posted January 9, 2015 Here is mine without lightening holes in a few different configurations. All the edges have a 1/4" roundover. Saw horses without crossmembers. They just work like a pair of regular saw horses Another configuration A compact configuration designed as a base for the torsion box low assembly table. The kiki pose. 5 Quote Link to comment Share on other sites More sharing options...
Mark J Posted November 24, 2016 Report Share Posted November 24, 2016 I like it, Terry. Very nice. What did you use to cut the components out of the 4 x 8 sheet? Track saw/Jig saw/Table saw? Also, did you ever put in the lightening holes? I am not sure I would. Quote Link to comment Share on other sites More sharing options...
TerryMcK Posted November 24, 2016 Author Report Share Posted November 24, 2016 4 hours ago, Mark J said: I like it, Terry. Very nice. What did you use to cut the components out of the 4 x 8 sheet? Track saw/Jig saw/Table saw? Also, did you ever put in the lightening holes? I am not sure I would. I did that with a regular crappy DIY quality circular saw and trimmed them to size on the table saw. Only bought a track saw in the last few months. I left out the lightening holes as I found they are unnecessary but I did put large radii on the ends of each of the crossmembers and longitudinal components. It makes it much easier to slide a sheet onto without fear of snagging on a sharpish edge. Quote Link to comment Share on other sites More sharing options...
gee-dub Posted November 24, 2016 Report Share Posted November 24, 2016 Very cool. Thanks for sharing that. Very versatile and breaks down to store in a minimum amount of space, I really like it. Quote Link to comment Share on other sites More sharing options...
TerryMcK Posted November 25, 2016 Author Report Share Posted November 25, 2016 I also use the knock down saw horses as a base for my torsion box low assembly table. I think I did a journal for that some where on here too but the photos are below. You can see that the top surface of the torsion box top is around 24 - 26" off the floor. Most furniture that we build is more comfortable to assemble at this height. The top of a chest of drawers is not too high that you need a ladder for instance. Also assembling tables or chairs is a breeze at this height. The top is simply placed onto the modular base and doesn't slide around. You could incorporate some sort of mechanical fixings (screws) but in practice I've not found it necessary. 1 Quote Link to comment Share on other sites More sharing options...
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