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Build a Pair of Versatile Sawhorses

Build a pair of furniture-quality sawhorses as you learn techniques you can use in intermediate-level furniture making.

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Build a Pair of Versatile Sawhorses

Build a Pair of Versatile Sawhorses

Build a pair of furniture-quality sawhorses as you learn techniques you can use in intermediate-level furniture making.

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About

These trestle-style sawhorses can support a work surface, extend the outfeed table on a table saw, or hold a rack of bar clamps steady as you arrange boards to glue up a panel. By freeing your hands to align the boards, the sawhorses help you achieve accurate, calm, trouble-free glue-ups. And with only a little adaptation, you can use the design to make a trestle table.

Learn how to:

  • Accurately mill parts from both solid wood and plywood
  • Use the small and large domino machines to cut mortises
  • Create bridle joints
  • Use a tapering jig on the table saw
  • Safely make plunge and stop cuts at a router table
  • Accurately repeat dado cuts

Details

  • A $200 materials fee, included in the class fee, covers all the materials you'll need.
  • Bring a clamp that you plan to use with the sawhorses for glue-ups. Or, if you haven't yet purchased clamps, the instructor can provide guidance on what to buy, and what widths to cut in the top bars.

Project

You'll build two sawhorses with a base of solid wood and a top rail of high-quality plywood.

The basic design has a top edge 36" from the floor, comfortable for tall or medium-height people (you can make it lower if you want). If you plan to use the sawhorses to support an outfeed table for a table saw you have at home, measure that height and bring it to the first class.

Prerequisites

Class Policies

  • Ages 14 and up are welcome.
  • You must wear safety glasses and closed-toe shoes, tie back long hair, and avoid loose-fitting clothing and jewelry. We recommend bringing your own safety glasses.
Instructor
John McCormack

John McCormack is a furniture designer, maker, and teacher living and working in Port Townsend. A graduate of the cabinet and furniture making program at North Bennet Street School in Boston, he holds a Master in Fine Arts in furniture design from Rhode Island School of Design. He has written for various publications, including Fine Woodworking, which featured his piece on The Ultimate Crosscut Sled on its cover. He got his start in woodworking by studying under John Kassay, author and expert on Shaker and Windsor furniture. Read more at his website: https://www.johnpmccormackdesign.com/

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