Author Topic: Homemade Saw Horse (Read 55952 times)

Sean Ackerman · « **on:** January 14, 2014, 08:59 AM »

Pretty cool video we just came across.

Legs remind me of a Powermatic 3520b. I really dig the "no wobble" thanks to the tri leg design.

basswood · « **Reply #1 on:** January 14, 2014, 09:48 AM »

Hi Sean,

Thanks for posting this. I'm glad you like the design.

This was my "things are slow in the shop" challenge for myself last winter... to build a sawhorse that could solve some of the problems that most saw horses have.

That drove the 3-legged design for the "no wobble" stability you mentioned. The thickness matches 2x lumber, so tools with rafter hooks can hang on or IN the rail (hooking them in the large holes so the top of the horses is available as a work surface).

The large holes have lots of other uses too (clamping, cord management, etc.)

I won't carry on about the other features, but would be happy to answer any questions anyone has.

They were in articles for FHB and TotT, so I can add links to those if anyone wants to find out more. I have a website where plans are available too.

Let me know if you want any of those things posted.

Thanks, Brian

SRSemenza · « **Reply #2 on:** January 14, 2014, 10:07 AM »

Brian, That is very cool!

What great design.

Yes, show and tell us more.

Seth

basswood · « **Reply #3 on:** January 14, 2014, 10:54 AM »

Hi Seth,

Here is the Tools of the Trade piece:

http://www.toolsofthetrade.net/homemade-and-modified-tools/clever-home-built-saw-horse-work-station_o.aspx?dfpzone=blogs.davidfrane&utm_source=newsletter&utm_content=jump&utm_medium=email&utm_campaign=TOTTU_010714&day=2014-01-07

The Fine Homebuilding article is a members only piece online, so unless you are a subscriber you only get the first 100 words (it is the Oct/Nov 2013 issue, if you have access to a printed copy):

http://www.finehomebuilding.com/how-to/articles/three-legged-sawhorses.aspx

Here is the website where you can get a 12 page PDF of the plans to build them (costs $10):

http://www.basswoodmodular.com/

We are putting most of the revenue from the plan sales back into the business so we can offer more and improved plans as people request them. This first set of plans is mostly for building 3 and 4-legged versions of the horses in various heights and lengths. Working on a cutting and clamping table now.

Thanks for the interest, Brian

Paul G · « **Reply #4 on:** January 14, 2014, 11:42 AM »

That's pretty cool, will be thinking of ways this might be integrated into my upcoming track saw table

basswood · « **Reply #5 on:** January 15, 2014, 03:00 PM »

I'll see if I can add some photos and brief descriptions to add to the discussion. This is a test, only a test.

basswood · « **Reply #6 on:** January 15, 2014, 03:03 PM »

That was not so bad.

Here is a shot of a Tri-Horse with a work piece clamped to it and a saw hanging from a rafter hook:

SRSemenza · « **Reply #7 on:** January 15, 2014, 03:32 PM »

Have you tried one with wide legs? The two leg part about 3' -4' wide so that one try horse could support sheet goods.

Seth

basswood · « **Reply #8 on:** January 15, 2014, 03:54 PM »

@Seth,

I have made a set of table legs for a banquet table that sounds similar to what you had in mind.

Had not thought to do this with the Tri-Horses.

SRSemenza · « **Reply #9 on:** January 15, 2014, 04:45 PM »

Something like this.

Seth

basswood · « **Reply #10 on:** February 06, 2014, 08:52 PM »

I posted my sawhorses as a project on the LJ site about a week ago and made it to the top of the "Hot Projects" page and received the "Editor's Choice" award.

http://lumberjocks.com/projects/96307

People really seem to respond to the design. I think the design is enough of a shift from what people have seen before that it surprises them and gets them thinking. This is what is good about it, when people have that sort of “ah-ha” experience they start coming up with more cool ideas on their own.

This brings the design to life with an infusion of fresh thinking. Some of the best ideas for this system may be yet to come and from people like you (like the version Seth posted).

All the best, Brian

CJ'60 · « **Reply #11 on:** February 07, 2014, 10:25 AM »

Brian, well deserved. I just ordered your plans.

Best, Karel

Frank Pellow · « **Reply #12 on:** February 07, 2014, 11:48 AM »

Brian, I really like the design. Well done.

basswood · « **Reply #13 on:** February 08, 2014, 01:18 PM »

Hi Karel and Frank,

Good to hear that you like the design. Nice to get orders for the plans too.

For those who might wonder, here is a description of the plans:

"The plans are a 12-page PDF that includes dimensioned drawings, photos, illustrations and instructions for building sawhorses in a range of lengths from 4' to 8', in heights of 30" to 36" and in both the three-legged "Tri-Horse" and in a more traditional 4-legged version.

The plans are primarily for the building of the sawhorses with some photos, illustrations, and suggestions about how to use them and accessorize them."

If anyone wants to do a "build thread" and discuss the process, let me know.

Thanks, Brian

Tinker · « **Reply #14 on:** February 09, 2014, 09:14 AM »

When i was 7 ft tall and in mason contracting biz, I did something like that using 2x6 lumber for scaffolding small jobs or where i only needed to get my ffet no more than 3 ft off the ground. Instead of using slots, i nail cleats on the horizontal cross pieces. the cleats were nailed at an angle as are your slots so the horses would bear agains the ledger pieces. If ground was level, i used four legs that would spread and make the joint tight against the sides of the ledgers. If ground was uneven, I had legs on one end of ledger that fit close at bottom so the scaffold ended up as three legged. for hight scaffolding, i had steel staging frames, but for small jobe, it was very quich setting up low staging and the method would support a lot of weight very substantially.

I really like your idea and it is so very adaptable for a lot of ideas and uses. great job.
Tinker

basswood · « **Reply #15 on:** February 17, 2014, 08:05 PM »

Tinker, Good hearing about the masonry scaffolding. Lumpy, bumpy and sloped terrain can make work "interesting". Sounds like you had a good setup.

Glad you like this design. I actually envision building loft beds, and other knockdown furniture using similar designs.

I'll post more photos here soon.

All the best, Brian

Tinker · « **Reply #16 on:** February 18, 2014, 11:30 AM »

Some times i wood use only the double legs at one end and the other end would be resting on scraps of wood or cement blocks. It was an adaptable system and if better stability was needed, I would add a few cross braces between the leg sets. Sometimes, the stages were placed to hold only the material and i was down on a lower level of ground. In that case, I used triagled 2x 's to keep the whole thing from pushing in to the space where I was working. That could get a tad uncomfortable. When in tight spaces, i did the scaffold setting up no matter how experienced the help.

I actually enjoyed the problems encountered with scaffold setups. Mistooks were not acceptable.
Tinker

basswood · « **Reply #17 on:** February 24, 2014, 09:57 PM »

Tinker,

I enjoy seeing well set up scaffolds. You are right, there is not much margin for error.

I used this set up this week to add conduit to the shop ceiling. Not enough room for a full scaffold set up so I used a plank on my horses:

RonWen · « **Reply #18 on:** February 25, 2014, 06:54 AM »

An outstanding design!

NYC Tiny Shop · « **Reply #19 on:** February 25, 2014, 08:18 AM »

basswood · « **Reply #20 on:** February 25, 2014, 09:22 AM »

Ron and NYC, Thanks for the compliment.

Here are a few photos of some of the setups these horses can be used for portable shop, adjustable padded work supports, stand-alone miter saw stand:

basswood · « **Reply #21 on:** October 11, 2014, 10:37 AM »

Here is some fun news, my sawhorse received a Core77 design award (runner-up):

http://www.core77.com/blog/core77_design_awards/core77_design_awards_2014_the_best_diy_designs_of_the_year_27402.asp

Working on a kickstarter now to get these into production.

Let me know if you have any thoughts or questions, thanks for the interest here! Brian

waho6o9 · « **Reply #22 on:** October 11, 2014, 10:44 AM »

Congratulations on the Tri-Horse System award!

Very good.

Peter Halle · « **Reply #23 on:** October 11, 2014, 10:45 AM »

Congratulations! I had forgotten about these. Time to order the plans.

Peter

basswood · « **Reply #24 on:** October 12, 2014, 10:19 AM »

Thanks Waho and Peter,

Of course the designs keep evolving. I recently added dog holes 6" o.c. to the top of the rails. This could be done on any 2x horse rails, not just with my horses.

basswood · « **Reply #25 on:** October 12, 2014, 12:01 PM »

I'll add the plans link here, if that is okay with the moderators. Not trying to be too forward about selling here. FWIW the plan sales so far have mostly just covered the cost of producing them and making them available (not that I mind making money). Hopefully this post puts most of the useful info about them in one place:

http://www.basswoodmodular.com/category-s/1477.htm

The plans are a 12 page pdf. and allow for building 4, 6, and 8' long horses in heights from 30-36" and in both 3 and 4-legged models, depending on what might work for you. I have made both short and and long horses in 3 and 4 legged versions for my work. If you decide to build them let me know and we can brainstorm what will work for you.

There are some, tips, drawings and photos of how to use and accessorize them included, but no accessory plans are available at this time. I am still tweaking some of those designs, but if you have questions, just ask.

The video also helps and the thread on LumberJocks has some additional info. We can add to the discussion here as well.

http://lumberjocks.com/projects/96307

Another note: Honestly these are pretty labor intensive to build, but the first one can be used as a full sized template once made, which helps.

basswood · « **Reply #26 on:** April 23, 2015, 08:06 PM »

Hello again,

You for your interest in these TriHorses. Many people all over the world (18 countries and counting) are now building their own version of these from the plans.

If you are someone who wants to have these, but would rather spend your time on woodworking rather than sawhorse building, we have launched a Kickstarter campaign to get these into production. If you would like to support the TriHorse design please check it out here and back us if you can and/or share this:

https://www.kickstarter.com/projects/trihorse/trihorse-sawhorse-and-workstation-production-run

Thank you so much! Brian

basswood · « **Reply #27 on:** July 08, 2015, 10:55 AM »

This is an add on that works with my TriHorse system. I designed and built a portable hybrid work bench, that is a hollow torsion box design with dog holes and integral side and tail vises. It works similar to a real woodworking bench, mounts on TriHorses and it doubles as a miter saw wing or table saw out feed, etc. This is the sort of accessory I would like to offer plans for and eventually add to our line of manufactured goods for sale. I am getting ahead of myself here, but this the future I imagine for this business, so stay tuned!

Let me know if you would like to see how I built this work bench. It is a bit of a cross between MFT and traditional work bench. I prefer a bench with a few less holes than MFT's and with the vises built in, less holes works fine.

Tinker · « **Reply #28 on:** July 08, 2015, 12:05 PM »

Quote from: basswood on July 08, 2015, 10:55 AM

This is an add on that works with my TriHorse system. I designed and built a portable hybrid work bench, that is a hollow torsion box design with dog holes and integral side and tail vises. It works similar to a real woodworking bench, mounts on TriHorses and it doubles as a miter saw wing or table saw out feed, etc. This is the sort of accessory I would like to offer plans for and eventually add to our line of manufactured goods for sale. I am getting ahead of myself here, but this the future I imagine for this business, so stay tuned!

Let me know if you would like to see how I built this work bench. It is a bit of a cross between MFT and traditional work bench. I prefer a bench with a few less holes than MFT's and with the vises built in, less holes works fine.

It just gets better and better.
I agree about not so many holes.
I have spent some time trying to find if there are other angles to be found in the MFT tops, other than 90º and 45º. I was unable to work out without using odd sized dogs which ended up with many complications. Too many starting points and too many odd sized dogs.
Maybe you could work out a couple of extra holes so commonly used angles other he 45 & 90 are quickly possible.

After sending a previous reply, I went out to my barn to see if I still had one or two of my old 3 legged setups kicking around. Since i have not had use for them in 25 or 30 years, i am sure they all got used for fire wood. Another use for them when they get al broken and splintered. Splintering was the biggest problem when used for masonry. plywood edges don't stand up so great with such battering from course materials and even coarser weather. Your design I am sure will stand the test of time for use as site workbenches and even for use in shops of any size.
Tinker

basswood · « **Reply #29 on:** July 08, 2015, 12:53 PM »

Hi @Tinker

I built this prototype bench with hardwood edges (maple), the field is a birch ply. For heavy use the bottom of the table has another set of dog holes, so long dogs can resister in both the bench top and bottom. With double dog holes it's pretty secure, even though lightweight. Clamped to these heavy horses gives the setup enough mass to work pretty well as a bench.

For odd angles and varying the set up for irregular shapes, etc., I have a cam-action, three-sided dog I use. Here is a photo of the bench with my TriDogs. These make the dog holes, that are on 4" centers, work like they are on 1" centers. The edges of the 3-sided dogs are 3", 2" and 1" from the dog holes. You dial in the desirable distance and it saves effort spinning the vise tight. Can also pivot to hold irregular angles or odd-shaped objects: