I kept thinking about the way to make a portable work table or workbench out of just one folding sawhorse I built, and kept running into the dead end, because it always seemed very complicated when I came up with the idea to attach the table to the sawhorse, since the top of the sawhorse is just too narrow, I have to brace the joints here and there, therefore, they all looked very “after-thought”. I know it would be much easier to just use both sawhorses, and it seems logical to have a conventional table after-all.
The other thought was, I didn't have any picture taken during the process of making the folding sawhorses, this will be another chance to show some details of assembly sequence for this type of simple joint.
Step 1: Modification Design
This first picture was my old design when I build the folding sawhorses. Click the Instructables link below if you would like to check it out.
My table saw is 38" high, and that's also a comfortable working height, so naturally the portable workbench in the future should be the table saw out feed support height at 37 3/4". The table top surface will be 3/4" plywood pieces, so the sawhorse supports should be 37". Thus, I need increase the sawhorses height by 8" from 29".
The ultimate goal is to have at least two if not three working heights available out of one set of sawhorses. The modification is to add two vertical pieces to make up the height, which I will call it sawhorse extensions. I thought about making another set with 37" height, but then I will loose the flexibility of having two workable heights with one set of sawhorses.
An 1” wide brace piece should be glued and screwed to support the extensions, and make the whole joint as a wide dovetail so it's worry free of pulling out in case I move the sawhorses just by grabbing the extension.
The horizontal movement of the extension should be restricted by the shelving that goes between the sawhorses, at this point, the concept is still under refinement, so a couple of clamps are the solution before the portable workbench get finalized.