Reposted from alt.home.repair
I'm trying to make a couple of folding sawhorses. My own design. :-)
(like there's not enough different sawhorses already.) Two 36" 2x4's for
the top, fastened together along 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, and the rip fence only attaches on the right of
the blade. I made a practice cut in a scrap of 2x4 and quickly found
the one little detail that I overlooked in my design. How do I cut the
notch on the other end of the 2x4s?
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...
Several possibilities. I can 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.
Or I can feed the board from the back WITH A STOP CLAMPED TO THE FENCE
in case it grabs the board and tries to pull it in. I don't like this
because either I'm reaching over the fully-extended blade or standing at
the back of the saw, but it might be OK with the stop in place. I could
also stand to the side of the saw; will have to test how awkward that is
(with the saw OFF, of course.)
Maybe I can use the little wedge scrap that I cut off as a shim under
the 2x4 so I can cut the end notches using a dado? It looks like it
What say the experts? There's probably really easy solution, but I'm
out of practice and can't see it. I'm liking the dado idea. A coworker
showed me his missing fingertip to remind me to be careful. Thanks.