Effi Cohen

DIY: Building a sawhorse with Ayden and Jess

FRAMES are up. Trusses are up. Steel is up. We've been cutting and fitting rafters all week.

The house is going swimmingly and I do mean swimmingly with the nasty weather we have experienced of late. I was on site on Saturday to check how everything was going and didn't even get out of the car. What a tremendous amount of water we have had, very heart wrenching too when you see all the hard work you've done be punished by the rain.

I cant wait to get the roof on. Come Monday, I thought I would do a clean-up only to find we had a lot of leftover stud material, all less than one metre so, instead of throwing them out, I made a new saw horse, seeing as though I've nearly chopped through mine and there is only so many times you can re-nail it.


This is the hardest step, I promise. Set your drop saw to a 15 degree mitre cut with a 22.5 degree compound mitre.

If your drop saw does not have the compound mitre function, you will have to cut them using a hand saw, protractor and a pencil. Cut one end of your timber then measure 850mm from the long point and mark with a pencil, now cut that end. Make sure you slide the timber through the saw and not move the first cut. Do this to all four legs.



Block star Ayden Hogan shows you how to build a sawhorse form off-cuts of timber.
Block star Ayden Hogan shows you how to build a sawhorse form off-cuts of timber.

STEP TWO: Table, end supports, stiffener

Cut a piece of timber 1m long. I'm making mine 1m long but you can make it smaller or larger. This will be your table. Now cut two pieces at 240mm and cut two parallel mitres on each of the ends at 15 degrees.

Make sure you reset your compound mitre back to 0 for this. Most mistakes happen when someone borrows your saw and doesn't lock the compound mitre back into 0, which can be frustrating when you have 100 straight cuts to do off a cutting list only to find out at the end it's not on 0.

Now cut a piece at 835mm, also with two parallel mitres on both ends. This will be the stiffener.


Block star Ayden Hogan shows you how to build a sawhorse form off-cuts of timber.
The Block star Ayden Hogan shows you how to build a sawhorse from off-cuts of timber.

STEP THREE: Assembly

Using a pencil, square and tape measure, mark a line at each end of the table 135mm in from the end. Now using your pilot bit, hold one leg on the inside of the line and pilot hole two holes through the leg into the table. Repeat this on all four legs and sides.

Using a battery drill with a hex head bit and your 75mm batten screws, fix the legs into place, two in each. Don't tighten them too much at this stage, just enough to hold the legs together. Using the same pilot hole drill bit, pre-drill the supports to each end, lining up flush with the legs. You'll only need one screw per leg. Tighten to the under side of the table with batten screws.

Place the stiffener to the under side of the table and hard against both stiffeners. Using the same method, fix off one through the bed and one in each of the stiffeners.

Now tighten the leg screws and you've built yourself an extremely sturdy saw horse to last you at least 20 years.