Cheap, Lightweight, And Super Strong! - Did I Accidentally Design The Perfect Saw Horse?
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- เผยแพร่เมื่อ 7 ก.พ. 2025
- Cheap, lightweight, and super strong! I set out to improve on an idea and ended up stumbling upon a design that I can see myself using for years to come.
A super strong and stable fold flat saw horse that doesn't take up too much space in my small single garage workshop.
In the workshop or on-the-go, I think this is a game-changer!
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Should you choose to make or do anything as depicted on this channel you would do so at your own risk.
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The rope brace is brilliant
Wow this is huge. I never comment but you nailed this one. A little imagination and this could transform a shop
There’s only a few great designers on TH-cam and your definitely up there well done once again
Remember, Measure Once, Cuss Twice!
I need this on a tee shirt!!
🤣🤣🤣🤣🤣 please TH-cam, add a laughing emoji 🙏🏿
*at least twice
Simple, true, and relatable
Never fails .
First: Once you have one saw horse cut out, you can use a bearing guided bit in your router to cut out the second and subsequent ones all in one go, no need to faff around with a jig saw and straight edge guides, just drill a few pilot holes for the bit - then you only have to worry about which direction you are routing in. Second: layout - on a 4x8 (1200x2400) sheet, you would get a stronger grid by putting both saw horse blanks head-to-tail - just rip the sheet down the middle, then cross cut the saw horse blanks apart. The now 2x8 (600x2400) can be easily rip cut into strips - with the long grain running end to end, because quality ply's maximum strength is parallel to the surface grain - potentially up to 8ft (2400) long and 4ft (1200) wide. CAD CNC programs always assume that the material they are nesting has no strength differential/orientation requirements (like MDF).
I am not sure how you see this first step; cutting a thick piece of plywood with a router bit, using that router he is using? You could and probably should take multiple rounds, but then it’s still hard work for that machine. I would use number 1 as a template for the next ones, cutting them out roughly and cleaning them with the router
@@TheHkluivertthey're are definitely bits (combined with beefier router) that can eat through that 3/4 ply in one pass, no problem.
But yeah, i always feel it's safer, easier on tools, and cleaner final product to do it in multiple passes... but that's still faster/easier with the one tool and process, so yeah, make one and "trace it" over and over 👍
Good suggestion.
I've used flat head machine screws and T-Nuts to mount hinges in this type of application, which results in clean look -- especially if you use a Forstner bit to do a very slight countersink to flush mount the t-nuts. These sawhorses are a nifty design!
Мужчина, Вы гений. Это прекрасно! Черт побери, это великолепно!
This build has so many uses . Quick on site table/workbench is one .
I been building saw horses for years never thought of this . Amazing I'm heading to the shop to build 😂
I started out in carpentry in the 70's. My favorite past time is watching these types of woodworking videos (you can always learn something new).
This is, without a doubt, the best saw horse design that I've ever seen.
You don't need them to "hold a ton". I've used upturned trash cans and tailgates as saw horses. They should be (relatively) sturdy, light and compact. This design hits those points better than anything else I've seen.
Que fantástico de cavalete ... JAÚ SP 🇧🇷 👍🏻 BRAZIL
Curious why you didn't make it so the top of the cross beams are level with the long beams on your support piece. At 12:04 that piece of plywood on top only has support from the three cross beams. If everything was level, it would be supported all around.
I think if he squared off the notches instead of leaving them round from the drill bit, they would have let the top sit flush on all 5 boards.
only suggestion I have is to use washers next to the plywood at the bolt heads & adjust the bolt length accordingly, maybe some sort of lock washer with the acorn nuts.
I'm impressed ... I've been looking at a lot of saw horse designs here on TH-cam, but yours and it's execution is far and away the most practical and elegant version I have seen. I will be making two sets of these in the near future, (and YES, I would appreciate the plans). Thank you for sharing, you have won my subscription and I look forward to viewing your back catalogue and other output ... "Well done that Man" 😎
Simple and yet very clever 👍
This design is a great take on the ply sawhorse, one of the best i have seen.
This is exactly what I need, thanks
the top piece of the sawhorse would be made with drop in top panels (sheet of plywood with cleats to lock into the frame) and then mount some tabletop tools as needed to the top for a portable worktable. I would make the tool tops as squares, so I could put a tabletop drill press, sander, surface planer, grinding station, etc on each and mix and match as I need. And of corse you'll need a storage system to hold the mounted panel parts when not in use...
Someone dumped a load of 2x4s in the lay-by opposite my house, and I made them into a table-top for my (pre-existing) saw horses, pretty much like yours, but a bit heavier. It has been really useful for when I'm working outside.
Your designs are just brilliant. I honestly wonder if you could patent this sawhorse design and commercialize it with some company. The top frame could definitely easily be modified to add some functionality - holes/slots for clamps, a mechanism to attach a sheet of MDF/plywood/chipboard/etc. for a lightweight and portable workbench surface, rails and support for a flattening jig, maybe? It's a super versatile design, I think.
Awesome project once again. You can see the careful thought put into this to optimise it to full capacit. An idea for the grid/frame might be to add some foam or rubber adhesive strips to add some clearance for the when you break down larger sheets. It could also help to cusion the work peice and prevent damage. The obvious addition would be some cut outs or ledge to acomodate clamps. That said i thi k it is an awesome idea and valueable addition to any workshop...
This channel deserves WAY more subs.
It earned another one today…
This looks like the basis for a nice lightweight portable work table/bench.
This is so much nicer than the clunky sawhorses I have from the big box store…🎉
You could use a foldable MfT design like the Bora dog hole top, and secure the top to the frame with a couple of well placed bench dogs to stop the sheet sliding around. (Might need to add a thicker bit of timber to allow for the bench dog hole on the cross beam)
This is an awesome design. I love the integration. For clamping, you could cut ovals into the sides of the upper frame to allow clamping points.
The only thing i hate about your videos is that they have to come to an end.. You always keep me wanting more. From a fellow Capetonian thanks for the great ideas and hard work.... Jy is n Yster !!
Those would actually be perfect for anyone who works out of a small sprinter van. They could easily fit behind a shelving unit or just behind the front seats. I think if you made a shorter version of the sacrificial top, it would be really useful for those times you need to plunge cut or drill through something.
I have a Ford van.
Slots toward the top would make great carry handles.
Love the compact clean design, and the fact you 4 horses, 2 little tables from a single sheet of plywood... awesome
Awesome idea
These are awesome! But to make them only 3/4 thick you could recess the hinges and flip them over so they are flat when closed. Beautiful design though!
I've been trying to design a work table that is large, sturdy, adjustable (height and for uneven floors), portable, and stow-able.
I had gotten the large, extra sturdy, and adjustable into the design. Not so much on the portable and stow-able. This video has given me some ideas. Thanks.
WOW - This is the 1st of your videos that I have watched. I will definitely watch more and will subscribe right away. I normally do metal working, but I can see use of some of your ideas across both venues
Your video was great and no horrible music in the background - A big thanks for that.
Great design, I think the top frame could be a proper portable assembly table.
Now that is cool. Makes so much sense especially when space in the garage / workshop is a premium. Cheers boet.
Nice! I feel like the top of the saw horses could be planed to be level when in the open position for a slight improvement. Great design and video, I'm all about trying to optimize yield so was glad to see you optimized for cutting from a single piece of plywood
Very neat design may build one for myself
T-nuts would have been a cleaner, stronger way to fasten your hinges. Cutting a relief and mounting them upside down would have been flatter.
Very much enjoyed this video and the project execution! I just came across your channel this morning and subscribed.
That was MAGICAL! Who needs a Bora Centipede when one can build this lovely bit of kit? Loads of strength plus easy storage.
And it looks great, too! I subscribed!
this seems to be a variation of the Ron Paulk Workbench (which i like even more)
Et bien j'aime bien la conception de ces tréteaux , qui ne nécessite qu'une feuille de contreplaqué, les supports de renforts encastrable ça c'est bien vu et sera toujours plus stable que des renforts juste Poser dessus.Offre un confort de stabilité qui n'est pas négligeable pour la sécurité lors de l'exécution de travaux . Bon bricolage.
brillant project
You are a genius sir!!! The design is utterly fantastic!!!
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super great plan to make a few thank you and god bless you
As usual great work and fantastic design👍❕❕❕
Great simple build. One suggestion is to use furniture connector bolts for the hinges, nice and flat profile will look neater.
I love this idea... Think I'll have to copy... Thanks for sharing. 👍😊
You always provide very interesting projects and content Jean. Thank you.
Make a template for rough out cuts, then flush cut router work.
With this you can duplicate these in mass kits, then sell them at shows
Or online order flat pack.
Really flat pack.
You could also sell a paper template and scratch up ditigtal copy someone could copy.
Also these can scale up.
Maybe a boat stand for dry land use with some changes for a boat.
Pure genius
Well done Jean - great use of ply sheet 👍
Loved this so I subscribed. South African? Nine video and I think the final bench would work great when cutting sheets of plywood iv you just put like floor insulation on the table first.
that ends up being a great collapsible work table too. nice job!
Probably the best version of something I’ve been searching for - until now I haven’t found the right fit for my tight workshop. Great design and even better video of the process - thanks for this.
New subscriber here. I love the saw horses you built. I'm gonna burn my 2 / 4 saw horses and build a set like you did. Thank you for sharing.😊
Brilliant video, shall make this at the weekend, thank you
Will be addig these to my workshop. BTW, nice socks 😀
Clever. It is worth noting that the length of the rope is critical to height of each saw horse, as well as the angle of the spread. And the angle of the spread is critical to the box fitting onto them.
That rope design was very clever!
Great Job!
Great concept well executed, with good audio and dialogue. Subscribed!
Nice saw horses
After watching several related videos, I believe that yes, you may have designed the perfect sawhorse.
Great video 👍
And thank you for the update on the workbench - I have been dying to see the next instalment as I am redesigning my workshop…I’d even appreciate just a conceptual drawing for now 😇🤣
well designed!
Love the subject, videography, clear presentation, subtle humor as well as no talking over machine noise or continuous background music. Subbed!
wow. You better patent that now before someone rips it off and makes their millions. Looks great, one suggestion add an extra thicker rib for the top. maybe 1-1/4" that is level and not on an angle. Love your channel!
Simply Brilliant!!!
For a small garage style work shop, this is brilliant! And you can do this from one sheet of plywood and not too many tools are required to complete the project. Something a beginner could try doing. Well done.
Fantastic! You should patent this flat-pack work bench. 💥
Greatings from France!
That's a perfect use of getting as much out of your material as possible, love that and how compact compared to traditional saw horses
Looks good
You Sir, are awesome. Keep it up. Looking forward to future videos. 👍
wow thats fantastic, the rope idea is brilliant but simple and it works perfectly.
That was beautiful, and then you unfolded the string and I immediately had to like the vid
Clever! I can't wait to see what you invent next. The notch in the middle of the stringers is a weak point. I think I will attach a tapered gusset just below that mid-span notch. I just downloaded the plans. A kindly comment - Dimensions is not spelled Dimentions
Wow! You are creativity by definition. 👏🏻
One word as always ...........Brilliant, you are the man!
Love that saw horse design. So easy to build and light weight. Once you have the first one done it’s a perfect router template for the other 3. Making the set super fast to whip up. 4 horses and 2 frames gives great support for 4x8 sheet goods. I made a set of Alexandre Chappels design a couple years ago. Yours are much easier to make and use a lot less wood. One benefit of his design is it gives a very useful shelf that acts as the brace instead of just the rope.
very smart.
Well done. Darlington, South Carolina USA
Muy buen proyecto.Te veo desde Sud America y disfruto tu explicacion.Gracias Amigo
Fantastic design. Well done.
You got a new sub for this project.
This whole set up was brilliant. The possible uses in a small shop area are great.
Nice design and excellent video. No elevated speed playback and real sounds. Thumbs up!
I like it very much!
Looks good, it's practical and space-saving. Nice work! :)
Great ideas from beginning to end. And from one who has made a few videos, your presentation is outstanding.
5:37 looks like screws to me,
Machine screws.
Great stuff! I don't know if you realize it, but this setup might just be perfect for us carpenters that work on big jobsites and use tool carts. It looks like every component can break down and be easily stowed away. I'm going to build a set as soon as I get some shop time on the weekend. I'll let you know how it works out. 👍🏻
hello - fellow saffo !
i think it's a truly wonderful design & very easy/cheap to build !
in my case,i simply use a couple of saw horses & an old door,as my work bench - on an overall basis,i think your design is truly great !
Thanks!👍
@@Nachoze70 Thank you!
So awesome! Worth replicating!
Fantastic fantastic I really like it
Brilliant, great idea for a portable work bench, I can just see a scenario where the bracing is sized so when you are on site can drop a job site table saw in and have an out feed table. The idea of the bracing on a bench for cutting and drilling is perfect for my needs, so thanks for that.👏
Brilliant!
This type of construction is very similar to the old vintage ping pong tables. Simple, strong and brilliant. Terrific idea.