THE 25 x 100 SAWHORSE

I built these to fit in the trunk of my ancient Chevrolet to assist me as I take my act on the road. You can pick up each with one hand. The I-beam top gives them strength and rigidity while helping them withstand the occasional nick from a saw.

I NSTRUCTIONS

Crosscut the three 1 25 x 100s for the top.

Tilt the table- saw blade 2 to 73˚, and run one 25 x 100 along a 50-tooth ATBR blade to put the bevel on each edge. Note: You reduce the width of the 25 x 100 slightly. You want to shave the bevel on it.

Leave the saw blade at 3 73˚ and crosscut the legs to length using a mitre gauge.

Begin making the top 4 sub-assembly by drawing lines that mark out where the horizontal pieces of the I-beam will need to attach to the vertical piece. Use a sharp pencil and draw a line down both the top and bottom surfaces of both horizontal pieces, the length of each piece, 35 mm in from each edge. This will give you a view on both sides. The lines on the inside surface help you position the horizontal and vertical parts. The lines on the outer surfaces (the top and bottom of your beam) tell

you where to drill pilot holes for the finish nails so that the nails hit the vertical piece.

Align and clamp 5 together the horizontal and vertical members of the I-beam, using the pencil lines to guide you, and make four 2 mm- diameter pilot holes through the top horizontal piece into the vertical piece. Flip the assembly over and repeat on the opposite side. Make a tick mark on the end of the assembly, spanning all three pieces, to be sure that when you glue and nail the parts together the

pilot holes stay aligned. Nail the top together. 6 First, spread a small bead of waterproof wood glue such as Titebond III Ultimate on the top edge of the vertical part of the I-beam. Don’t overdo it. The more glue you spread the more slippery things get. Check your tick marks, then start a 65 mm finish nail in one of the pilot holes; bring the I- beam parts into alignment and partially tap in the finish nail. Check the opposite end for alignment and partially tap in a finish nail there. Double- check alignment, drive the two nails home, and finish with

the center nails. Repeat on the opposite surface to complete the I-beam. Fasten the legs to the 7 sawhorse by marking 100 mm in from the ends of the I-beam. Fasten the legs to the I-beam with glue and 4 x 60 mm wood screws.

Mark and cut the two 8 gussets on a miter saw. Attach each gusset to the legs with glue and 4 x 60 mm wood screws. Gently round sharp 9 corners with a sanding block, including the bottom of the legs, which see the most abuse.