sawhorses - Wood Tools

After installing the ledges, cut thehorizontal stiffeners (D) to lengthfrom 1x4 stock.Then screw them tothe bed, as shown.Guide Rails - The next componentsto add are two guide rails (E)made from 2x stock.The lunlber forthese guide rails must be straight.Otherwise, the saw carriage will bindduring the cut.You'll want to getthe straightest 2x6 you can find, andthen rip both guide rails from it.Once that's done, cut a rabbet inthe back inside edge ofeach ra1l (BcdAssembly).-lhese rabbets form a trackfor the carriage to ride in (TopWuu).A11 that's left to cor.nplete theguide rails is to drill the holes thatwill be used to nrount then.r to thepanel saw. Eventualiy each rail getsscrewed to a cieat, which is in turnattached to the top ar.rd bottontiedges. This requires drilling deepcounterbored shank holes for themounting screws (Tbp Victu).Although the guide rails are conrpleteat this point. its best to waituntil after you make the carriage toattach them. That way, you can Llsethe carriage to establish the spacingbetween the rails.Add the Cleats -There's noneed to wait to add the nvo cleats (F)though. Cut them fron.r 1x4 stock tomatch the height of rhe bed. rndattach them to the top and bottomledges.Two screws secure the cleatsto the bottom ledge. On the top,however, a single lag screw passesthrough an oversize hole drilled inthe cieat.This les you adjust the locationof the guide rails if necessary.Carriage Support Pin - Aftermounting the cleats, the last thingto do is to make a pin to supportthe carriage above the workpiece.The pin is a short steel rod securedin the end of a dowel with epoxy. Itfits into one of two holes drilled ineither cleat (Guide RaiI Detail).Usethe lower hole for 48"-wide sheetsand the upper hole for Baltic birch,which is 60" wide.t1o,' x2,'log Screw&74" Wosher-\#8x l/a" Fh \tWoodscrewfto" robbet,72" deepGuide Roilllth" x2Vz"x76Vz"lNOTE: Mount guideroils oFeryou mokecorrioge (poge 26)Woodscrew,lGY'Cleot1t1o', a312,' x7B',1BED ASSEMBIYl3Z" deep, L-Is/sz"shonk hole -l 7zcenlered inside\@Bqckerl3/l'x3Vz"x78"1Stiffenerl3h" x3Vzx22rh"lI L15Y2"IEdf I15Y2"(1) 4'x8' sheet of 3/a" plywood(1) 8'-long 2x6('l ) 8'-long 2x4(5) 8'-long lx4sWWW.WORKBENCHMAGAZINE. COM 25