Mother's Folding Sawhorses

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Slots must be cut into the inside of each leg at all four bracket mount points, so the 1/8"-thick metal supports can be slipped in and pinned into place and so the bottom bracket can fold up. If you happen to have a table saw, the lower slots can be made by simply placing the wood over the retracted blade of the saw and then gradually raising the cutter to slice a groove slightly more than halfway through the board. (The same basic cut can also be accomplished with a saber saw and some hand work.)

However, each upper recess should be made by first drilling 1/4" holes in the center of the inside face, 3/4 inch above and below the pivot point for the steel. Then just cut out a slot between the two holes, so that the strap can be inserted and pinned into position.

Once you've bored out the pivot holes in both the legs and the steel straps, hammer 1-1/2" lengths of 1/4" rod in place to secure the pieces and lay the assembly flat on your workbench. Now place the legs at full extension, set the end of the 2 X 4 crosspiece against the legs at the upper pivot, and mark the cut necessary to pinch the board in the wooden "jaws". (Hint: When you shape the upper angle, be conservative about the amount of material removed. You can always file the surfaces down to achieve the appropriate fit.)

To put the finishing touches on your hideaway sawhorses (they work best in pairs), just cut a slot two inches from each end of the 2 X 4's (so that the top metal strap on each pair of legs can slide into the groove), glue some sandpaper to the clamping surface of each support, and lock the pieces into position. Now you're ready to trim wallboard, section plywood, or cut lumber with ease . . . and when the job's done, the stands can be folded up and stashed away for future use.

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