I'm trying to make a couple of folding sawhorses. My own design. :-)
Two 36" 2x4's for the top, fastened together at the bottom edge with a
pair of door hinges. On each end of each 2x4, I'll cut a 20° angled
notch 5 1/2" wide to inset a 30" long 1x6". (and the 1x6's will have
their ends cut at 20° to make them sit better on the floor and look
neater at the top.) When the sawhorses are set up, the legs will splay
out and the 2x4's will close up the gap at the top. When they are
hanging on the garage wall, the top will open up to a 40° V and the legs
will hang down. If my geometry is right, when they are set up they'll
be about 28" tall.
I'm using a 10" tablesaw to make the cuts. The blade only tilts to the
left for angled cuts, with the fence on the right. I made a practice
cut in a scrap of 2x4 and quickly found the one little detail that I
overlooked in my design.
I fed the 2x4 into the blade to a depth of 5 1/2", removed it from the
saw, and finished making the cut with a hand saw. Looks pretty good
even tho' I haven't cleaned it up with a chisel yet. (the 1x6 leg will
eventually be attached with construction adhesive and roofing nails.)
Now how do I make the cut on the other end? I can't safely feed the
board in from the back of the saw...
I think what I have to do is measure with the saw all the way up, lower
the blade, clamp the board to the back of the fence, turn the saw on and
raise the blade to make a plunge cut.
Maybe there's a way to use the little wedge scrap that I cut off as a
shim under the 2x4 so I can cut the other end with a dado? Or set the
blade back to vertical and use the shim on the rip fence?
I'm sure it's really easy, I'm just out of practice. :-/