Heavy Duty Adjustable Height Saw Horse

These folding saw horses are adjustable from 2' to 4'. The legs have a wide stance (25 degrees) for stability at full height and they are each hinged on a heavy duty 3 1/2" door hinge. The legs are cross braced by Simpson Strong Tie straps that hook into screw heads.
The adjustable upper frame is joined with half-lap joints and is tightly fitted in two mortises in the base and are held in position with carriage bolts in offset holes every 1 1/2".
These bolts also secure the legs in the stowed position.
The upper frame can be set on an angle to adjust for uneven terrain.
Made from dimensional 2x4 and 2x6 lumber and weighs 30lbs each.

Attachment 24784Attachment 24785Attachment 24786Attachment 24787Attachment 24788Attachment 24789Attachment 24790

A very clever design, indeed. I especially like the fact that the working height of the support is adjustable. Most saw horses I've used are just too low to permit working comfortably.

Have to Agree with Marv the adjustable height is a plus being able to use them on a step or with 1 side raised is another nice addition.
I would feel a little uncomfortable using them in the full elevated position as a scaffolding but as always the user must exercise care and caution when working on any elevated platform.

Very nice take on a common but often lacking tool build.

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Originally Posted by mklotz

A very clever design, indeed. I especially like the fact that the working height of the support is adjustable. Most saw horses I've used are just too low to permit working comfortably.

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Although I understand why something like kitchen countertop heights are a necessary compromise, standard worksurface heights seem to be unusually low. Not sure why. We have reliable, longstanding data on average human heights, our understanding of ergonomics is well-developed, and we know that lower back pain is both extremely common and costly. Economic incentive to produce worksurfaces with less material, which are thus less expensive? Lingering holdover from an era of universal 36" heights?

Jon I worked in a shop once where all of their work tables were 32" I'm not particularly a tall man 5' 11" but I found those tables ludicrously low. I learned that they were that height because the workers liked to sit while working. DO What? this is a fabrication factory where you are constantly loading items on a fit up table then welding them together Chairs are for offices and desk jobs was what I told the foreman. He and I made me a heavy duty work table over one weekend @ 38" in height. you didn't find a stool or a chair in my area.

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Originally Posted by Keith William Knull

These folding saw horses are adjustable from 2' to 4'. The legs have a wide stance (25 degrees) for stability at full height and they are each hinged on a heavy duty 3 1/2" door hinge. The legs are cross braced by Simpson Strong Tie straps that hook into screw heads.
The adjustable upper frame is joined with half-lap joints and is tightly fitted in two mortises in the base and are held in position with carriage bolts in offset holes every 1 1/2".
These bolts also secure the legs in the stowed position.
The upper frame can be set on an angle to adjust for uneven terrain.
Made from dimensional 2x4 and 2x6 lumber and weighs 30lbs each.

Attachment 24784Attachment 24785Attachment 24786Attachment 24787Attachment 24788Attachment 24789Attachment 24790

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Very nice indeed!! These are something I could use on the my ranch in Texas. Do you have any plans drawn up them?

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Thanks Keith William Knull! We've added your Adjustable Height Sawhorse to our Sawhorses category,
as well as to your builder page: Keith William Knull's Homemade Tools. Your receipt:

<div id="blocks"> <div class="block b1 pngfix"> <div class="bimg"> <div> <a href="http://www.homemadetools.net/homemade-adjustable-height-sawhorse"> <img src="/uploads/216110/homemade-adjustable-height-sawhorse.jpeg"/> </a> </div> </div> <div class="head pngfix"></div> <div class="left pngfix"></div> <div class="right pngfix"></div> <div class="blockover b1 pngfix"> <div class="title"> <a href="http://www.homemadetools.net/homemade-adjustable-height-sawhorse">Adjustable Height Sawhorse</a> <span> by <a href="http://www.homemadetools.net/builder/Keith+William+Knull">Keith William Knull</a></span> </div> <div class="tags">tags: <a href='http://www.homemadetools.net/tag/sawhorse'>sawhorse</a> </div> </div> </div> </div>
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Originally Posted by Frank S

Jon I worked in a shop once where all of their work tables were 32" I'm not particularly a tall man 5' 11" but I found those tables ludicrously low. I learned that they were that height because the workers liked to sit while working. DO What? this is a fabrication factory where you are constantly loading items on a fit up table then welding them together Chairs are for offices and desk jobs was what I told the foreman. He and I made me a heavy duty work table over one weekend @ 38" in height. you didn't find a stool or a chair in my area.

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Workbench height really really depends on what you're doing and what tools you use on it Chris Schwarz on Workbench height. (the whole article is a good primer on workbenches. Woodworking in this case, but applicable to all sorts)

Again what you're doing dictates whether you sit or not. (also age of joints and condition of knees etc :-)

Very nice sawhorses; vastly superior to my ancient '2x4 + wobbly sheetmetal sawhorse brackets' pair. What is that yellow and black clamp set I see in pics 2 and 3? I think I shall look into my supply of lumber and build a paor of these to replace 'em.

Quote:

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Originally Posted by Keith William Knull

The adjustable upper frame is joined with half-lap joints and is tightly fitted in two mortises in the base and are held in position with carriage bolts in offset holes every 1 1/2".
Attachment 24785

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bruce.desertrat asked about a yellow and black item on the elevating 2x4. Aren't those clamping devices, more or less like a pipe clamp but fit lumber? That's another outstanding feature of your horses. I avoid the molded horses for one reason; useless for clamping to the top. Use of hinges, tie-bar strut, leveling feature...what an array! I'm thinking these didn't just happen overnight

Congratulations Keith William Knull - your Sawhorses are the Homemade Tool of the Week!

This was a very difficult week on which to win, especially with a fairly common tool such as a sawhorse. There was both a high volume of tools, and a large number of tools with many Thanks votes. However, upon reviewing the 85 sawhorses in our Homemade Sawhorses category, this one stood out because it appears to be either among the best, or simply the best design we've seen. Specifically: stability, collapsibility, and adjustability - both in regard to height and uneven terrain.

Some nice picks from this week:

Square Stock Collet Inserts by mklotz
Round Stock Vise by rossbotics
Machine Badge by earz
Pipe Bender Die Guide by Frank S
Tool Handle for Arthritic Hands by philipUsesWood&Brass
Knurling Tool by Stevohdee
Belt Sander by Radioman
Watchmakers Lathe Threading Slide by threesixesinarow
Bench Block Ring Saver by mklotz
Bearing Installation Tool Handle by Frank S
Drill Press Lathe Chuck Mount by Rorschach
Vise Restoration by Make Everything
Slide Hammer Bearing Puller Adapter by Frank S
Stump Jumper Removal Press by Imabass
Single Hole Spanner Wrench by Frank S


Keith William Knull - we've added your tool entry to our All Homemade Tool of the Week winners post. And, you'll now notice the wrench-on-pedestal award in the awards showcase in your postbit, visible beneath your username:

https://www.homemadetools.net/forum/...OfTheWeek4.pnghttps://www.homemadetools.net/forum/...eWeekIcon4.png

You'll be receiving a $25 online gift card, in your choice of Amazon, PayPal, or bitcoin. Please PM me your current email address and gift card choice and I'll get it sent over right away.

A look through all of Keith William Knull's tools (viewable via the "Keith William Knull's Tools" link in his postbit) reveals that, like many of our tools, this one is likely the culmination of multiple similar builds. In fact I believe I see the folding ladder work table doing double duty in this build as a scaffold.

<div id="blocks"> <div class="block b1 pngfix"> <div class="bimg"> <div> <a href="https://www.homemadetools.net/forum/free-standing-truck-bed-slide-29914#post40985"><img src="/uploads/133466/homemade-free-standing-truck-bed-slide.jpeg" alt="Free Standing Truck Bed Slide"></a> </div> </div> <div class="head pngfix"></div> <div class="left pngfix"></div> <div class="right pngfix"></div> <div class="blockover b1 pngfix"> <div class="title"> <a href="https://www.homemadetools.net/forum/free-standing-truck-bed-slide-29914#post40985">Free Standing Truck Bed Slide</a> <span> by <a href="/builder/Keith+William+Knull">Keith William Knull</a></span> </div> <div class="tags">tags: <a href="/tag/2x4">2x4</a>, <a href="/tag/portable">portable</a>, <a href="/tag/workbench">workbench</a>, <a href="/tag/casters">caster(s)</a>, <a href="/tag/pickup">pickup</a></div> </div> </div> <div class="block b1 pngfix"> <div class="bimg"> <div> <a href="https://www.homemadetools.net/forum/folding-work-table-truck-bed-extender-29988#post41100"><img src="/uploads/133542/homemade-folding-ladder-work-table.jpeg" alt="Folding Ladder Work Table"></a> </div> </div> <div class="head pngfix"></div> <div class="left pngfix"></div> <div class="right pngfix"></div> <div class="blockover b1 pngfix"> <div class="title"> <a href="https://www.homemadetools.net/forum/folding-work-table-truck-bed-extender-29988#post41100">Folding Ladder Work Table</a> <span> by <a href="/builder/Keith+William+Knull">Keith William Knull</a></span> </div> <div class="tags">tags: <a href="/tag/portable">portable</a>, <a href="/tag/workbench">workbench</a>, <a href="/tag/extension-ladder">extension ladder</a></div> </div> </div> <div class="block b1 pngfix"> <div class="bimg"> <div> <a href="https://www.homemadetools.net/forum/folding-out-feed-table-portable-table-saw-48662#post69448"><img src="/uploads/154265/homemade-folding-outfeed-table-6.png" alt="Folding Outfeed Table"></a> </div> </div> <div class="head pngfix"></div> <div class="left pngfix"></div> <div class="right pngfix"></div> <div class="blockover b1 pngfix"> <div class="title"> <a href="https://www.homemadetools.net/forum/folding-out-feed-table-portable-table-saw-48662#post69448">Folding Outfeed Table</a> <span> by <a href="/builder/Keith+William+Knull">Keith William Knull</a></span> </div> <div class="tags">tags: <a href="/tag/2x4">2x4</a>, <a href="/tag/table">table</a></div> </div> </div> </div>

Glad you like them. I don't have any plans, sorry.

Wonderfully clean, well thought out, function-driven design. And the heavy duty door hinges no doubt supply ease and precise operation, while contributing to the strength and stability of the overall design. Your photography is super, as well. I've never seen anything quite like it. Thanks for sharing.

Quote:

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Originally Posted by Keith William Knull

The adjustable upper frame is joined with half-lap joints and is tightly fitted in two mortises in the base and are held in position with carriage bolts in offset holes every 1 1/2".
These bolts also secure the legs in the stowed position.
The upper frame can be set on an angle to adjust for uneven terrain.

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What dimensions are your mortises if they are tight fitting, yet permit the top to be set to different angles as the terrain requires? I'm definitely going to build a set of these. Thanks!

The mortises are tight fitting along the 3 1/2" faces of the 2x4 for lateral stability. The length of the mortise is approx. 4 inches, allowing 1/2" of play.

Attachment 24974

*design modification*

After leaving the horses in the rain, the wood swelled which made the height adjustment really stiff.
So, I just made a relief cut through the end of the 2x6 to loosen the fit and added a* through bolt and knob to tighten as needed to retain lateral stability after adjustment.

I think if you're using these outdoors, this mod is definitely required.