Knockdown Trestle Sawhorses | Popular Woodworking Magazine

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Simple design. Robust construction.

Any store he needs a pair of trusty tripods. I like the ones that are easy to build and easy to store.

Easy to do. All parts are only 1×4 of the house center glued together.

These easels definitely fit that bill and nest quite well too.

Removable feet. Unscrew the knobs to remove the feet.

This unique design is affordable for any carpenter and doesn’t require many tools to build.

Store plate. Hang the parts on a wall or put them on a shelf.

Wood is quite common: I used 1×4 yellow poplar from the local home center. You will need about 200 linear feet of 1×4 to make a pair of horses.

Trestle Knockdown Sawhorse Cut List

Overall Dimensions: 27-1 / 2 “H x 24” W x 18 “D

Part

First name

Qty. for 2

Thickness x W x L

A1

Leg 1

4

3/4 “x 3-1 / 4″ x 26-3 / 4 ”

A2

Leg 2

4

3/4 “x 3-1 / 4” x 14-1 / 4 “

A3

Leg 3

4

3/4 “x 3-1 / 4” x 6 “

B1

Upper stretcher 1

2

3/4 “x 3-1 / 4” x 24 “

B2

Upper stretcher 2

2

3/4 “x 3-1 / 4″ x 11-1 / 2 ”

B3

Upper stretcher 3

4

3/4 “x 3-1 / 4” x 3 “(a)

C1

Medium stretcher 1

2

3/4 “x 3-1 / 4” x 19-1 / 2 “

C2

Medium stretcher 2

2

3/4 “x 3-1 / 4″ x 11-1 / 2 ”

D1

Foot 1

16

3/4 “x 3-1 / 4” x 8-1 / 4 “(b)

D2

Foot 2

4

3/4 “x 3-1 / 4″ x 18 ”

D3

Foot 3

8

3/4 “x 2-1 / 4″ x 2-1 / 4 ”

Notes:
a) First miter cut on both ends of two 12 inch long pieces,

then cut them crosswise to create four B3 parts.

b) Rough cut four 17 ″ long pieces to make all eight pieces.

Building the horse

1. Use lots of clamps to glue the pieces together. Place two clamps on the pieces to line them up. To prevent these clamps from sticking to the wood, place a few small blocks, covered with masking tape, between the wood and the clamp.

You will need a table saw, a handsaw, a drill, and a set of clamps. A miter saw would be useful for cutting parts to size. Start by cutting all parts except A3 and B3 – you will cut them to fit later. Assemble the parts in the order shown in the drawings on the next page. The basic idea is to glue the pieces in layers (Photo 1), then tear off both sides to make the edges perfectly even (Photo 2).

2. Saw both sides of the glued parts. This is an easy way to make the edges perfectly even.

Here are some notes to guide you along the way. In step 12, you will glue one foot so that it fits snugly against one leg. The best way to do this is to place one leg between the foot pieces while gluing. Block these three pieces to bring them closer. To prevent the leg from sticking to the foot, place shims under the leg as shown in the drawing.

When you are ready to assemble the frame in step 16, place the stretchers in place and measure the distance between them. Size A3 to this length. You can glue all of these pieces together at once, but it’s easier to do this in two steps. Start with the middle stretcher, but leave the upper stretcher in place, without glue, so that the legs are properly spaced. Draw all the tight pieces with the clamps. For the second step, glue on A3 and the upper stretcher. After removing the clamps, cut part B3 to the exact length.

To install the suspension bolts, first drill a 5/16 “hole through each foot. Make sure the hole is plumb – it is best to use a pillar drill. Clamp the foot onto the leg and continue drilling the hole with a drill. Remove the foot and enlarge the hole with a 3/8 “bit. Install the bolt of the hook by locking two nuts together on its threaded end; turn them with a wrench.

If you finish or paint your easel, let go of your feet. You don’t want a film about the part of the leg that slips into the foot. That extra thickness would make the fit too tight – I know, it happened to me!

Buy the knobs for this project on Amazon


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