Crafting A Sturdy Table With Saw Horses: A Comprehensive Guide

Building a table with sawhorses is a fun and easy DIY project that can be completed in just a few hours. With some basic tools and materials, you can create a stylish and functional table that fits your unique style and space. In this article, we'll guide you through the simple steps to build your own sawhorse table, offering tips and tricks along the way. Whether you're a seasoned woodworker or a beginner, this project is a great way to add a touch of industrial chic to your home without breaking the bank.

Cut wood to size, using a saw

To build a table with sawhorses, you'll need to cut your wood to size using a saw. Here's a step-by-step guide on how to do this:

First, gather your materials. You'll need several 2x4s, a plywood sheet for the tabletop, and some additional hardware like screws and brackets. Decide on the dimensions of your table and mark the cutting lines on the wood with a pencil.

When you're ready to cut, use a circular saw, miter saw, or hand saw to cut the 2x4s to the desired length for the legs and crossbeams. The number of pieces you need will depend on the size and design of your table. For example, for a standard sawhorse table, you might need eight 30-inch pieces for legs and six 32.5-inch pieces for the central I-beam. Cut the pieces to size, ensuring straight and accurate cuts.

If you want angled legs for your table, you'll need to mark the angles on the wood before cutting. For countertop-height tables, each sawhorse leg should be around 32 inches long, with one end cut at a 55-degree angle to create a stable base.

After cutting the pieces to length, you can further refine them by sanding the edges. Use sandpaper or a palm sander to smooth out any rough spots and create a finished look. This step is important for both the aesthetics and safety of your table.

Once the pieces are cut and sanded, you can move on to assembling the table frame. Follow the instructions provided with your chosen bracket system, ensuring a secure fit for the legs and crossbeams.

Remember to work in a well-ventilated area when cutting and sanding wood, and always prioritize safety by wearing appropriate protective gear, including eye protection and gloves.

Smooth surfaces with sandpaper

Choosing the Right Sandpaper

Sandpaper comes in different grades of coarseness, and you should use three grades for this project: coarse, medium, and fine. The coarseness of sandpaper is measured in "grit", with higher grit numbers indicating finer sandpaper. For this project, you will need sandpaper with grits of 180 and 220.

Sandpaper also comes in different materials, each of which is better suited for particular types of sanding:

• Garnet is a natural abrasive used for sanding any kind of bare wood.
• Silicon carbide is best for sanding down joint compound and removing specks of dust trapped under your wood finish.
• Aluminum oxide can be used to sand down wood, metal, and paint.
• Ceramic is mostly used for power sanding and is one of the most durable and expensive abrasives.
• Alumina zirconia is a hard and durable abrasive used with machines that have a disc or belt.

Sanding the Table

Before you begin, make sure you are working in a well-ventilated area. You can use a sanding block to make the process faster and more efficient. A sanding block is something you wrap the sandpaper around, such as a piece of cut-out foam, a wooden block, or a block of cork. Fold the sandpaper around your sanding block and staple or glue it in place.

Start with the 180-grit sandpaper to remove obvious imperfections. Apply pressure to the sandpaper or sanding block with your hand and run it across the surface of the table, sanding with the grain of the wood. Don't forget to sand the edges and corners as well. Vacuum the accumulated dust when you're finished.

Repeat the process with the 220-grit sandpaper. Your table should now be perfectly smooth, with no scratches or dings. If you still see scratches, start the process over again, beginning with the coarse-grade sandpaper.

Alternative Methods

If you prefer not to sand by hand, you can use electric sanding tools such as a random orbit sander, belt sander, or benchtop sander. These tools are useful for larger projects or if you have a lot of excess material to remove. However, avoid using electric sanders for smaller projects as they can ruin your piece.

You can also smooth the wood without using sandpaper at all. Alternative methods include using sand and a piece of leather or cloth, pumice, walnut shells, wood shavings, or even building a primitive sanding tool with sand and a stone.

Paint or stain the wood

Painting or staining the wood is an important step in building a sawhorse table. The first step is to decide whether to paint or stain the wood. Both options have their own advantages and disadvantages.

Painting the wood

Painting the wood can add pops of colour to the table and is a great way to transform a shelf, wood floor, or mantle without spending a lot of money. However, painting requires more upkeep as it chips more easily than staining. If you are considering painting something like a hardwood floor, you will see more peeling and chipping, and it will require more touch-up work than staining.

Staining the wood

Staining the wood will allow you to retain the natural look of the wood. It is also easier to DIY than painting. Staining usually only requires one coat, whereas painting requires multiple coats. Staining is also more durable and wears off slowly without chipping or peeling.

Once you have decided whether to paint or stain the wood, the next step is to prepare the wood. This involves sanding the wood to smooth out any rough edges and removing any dirt or residue. After sanding, you should wipe down the wood with a damp cloth to remove any remaining dust.

If you are staining the wood, you can proceed to apply the stain of your choice. Be sure to follow the instructions on the stain container and allow adequate time for the stain to dry.

If you are painting the wood, you will need to prime the wood before painting. This will help the paint adhere better to the wood. Once the primer is dry, you can begin painting the wood with your chosen colour. Allow adequate time for the paint to dry between coats.

Assemble the legs and beams

To assemble the legs and beams for your sawhorse table, follow these steps:

First, cut your 2x4s to size. You'll need eight 30-inch pieces for the legs and six 32.5-inch pieces for the central I-beam. If you want your table to be counter-top height, cut your legs to 32 inches. For added stability, cut one end of each leg at a 55-degree angle.

Now, use a table vise to hold the 2x4s in a well-ventilated area. Cut them to size using a Dremel Ultra-Saw, which is perfect for simple straight cuts. If you want to cut notches into your legs to accept the stretcher, use a bandsaw or a circular saw and chisel. Smooth all surfaces with sanding blocks and sandpaper, starting with 180 grit and progressing to 220 grit. Remove dust and dirt with tack cloth.

Next, assemble the I-beam. Attach three of the 32.5-inch pieces together in a "T" shape using wood screws. Secure the bottom piece to the "T" with more wood screws.

Now it's time to attach the legs. Place the end of each leg just underneath the "T" and attach it using four wood screws in a box shape. Make sure to use a pre-drilled pilot hole to prevent the wood from splitting. Repeat this process for all four legs, then turn the sawhorse onto its legs. Check that it is well-balanced and secure.

Finally, add the stretcher for extra support. Center the stretcher on the bottom support and pre-drill and screw it into the stretcher. Your sawhorse base is now complete!

You can now attach your tabletop of choice to the sawhorse base. For a removable tabletop, consider using a plywood top secured with bolts and wingnuts.

Secure the tabletop to the sawhorses

Now that you have your sawhorses and tabletop ready, it's time to secure them together.

Place the plywood on top of the sawhorses and use a pencil to mark the edges of the top of the sawhorse onto the plywood. This will help you know where to drill the holes for the screws.

Drill holes into the tabletop and the pieces of wood that make up the top of the sawhorse legs. Make sure to pre-drill these holes to prevent the wood from splitting.

Use 2-inch or 3-inch screws to attach the tabletop to the sawhorses. Screw through the markings of where the top of the sawhorse is underneath.

Check the balance of the table before placing anything heavy on it. You can also add a wall anchoring kit to ensure the table doesn't tip over and cause any injuries.

Frequently asked questions