Assembly (3 of 3): Adjustable Top

Step 6: Assembly (3 of 3): Adjustable Top

The Top Assembly:

First, attach the bottom with the supports with 2 1/2 inch wood screws (recommended to pre-drill the holes). I put 2 screws in each side. See the picture for how I used clamps to keep it all in place.

Next, slide those pieces into place and clamp the Top of the 'Top Assembly' to the rest of the saw horse while also clamping the Top Supports so they don't move while drilling holes through the Top.

(See the pictures for more detail)

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paulbsa says: Mar 29, 2012. 12:42 PM

Good design, but it looks like this would be extremely heavy. Great for fixed use in a woodshop, but I would hate to have to continually carry these around to job sites. I wonder if some of the 2X lumber could be replaced with 1X. I agree about using bolts and nuts in place of the wood dowels and pins. You could also use something like a hitch pin from a trailer that would be secure but easily removable.

skirmishmonkey says: Jun 21, 2012. 5:59 AM

You are right (see my set below). These are very heavy - although I prefer the word robust. Not really suitable for moving around too much.

I am thinking about making a second set with lighter (thinner) lumber.

Saying that though, these are great for heavier duty tasks and to use around the workshop. I have even used them as a work platform with planks resting on them. (Probably not recommended for environments where the HSE officers breathe down your necks). One extended easily takes my weight (80kg) - again probably shouldn't recommend trying it at home.

The adjustable height is brilliant. I use the wooden dowels and haven't had any issues with them. If you drill the holes to the size of the dowels for a tight fit and make the dowels stick out a few inches either side then you shouldn't have any issues with them coming out mid task.

pbates123 says: Feb 5, 2012. 2:08 PM

Wow Great design Lofty Duck!! I see this is has been here for awhile although I just saw it. I want to make a couple for myself and maybe even a couple for a gift!

I had a couple of thoughts. Not having built a set yet it seems it maybe a bit wobbly once it is extended past the lower brace. If you were to route a dado on the inside of the legs say ~1/2in. wide and deep facing toward the slide on both sides, and on the slide near the bottom maybe an inch up drill a 1/2in. hole and insert a short piece of dowel. It would ride in the dado and help stabilize top assembly.

Also adding a couple of heavy duty hinges would allow the legs to fold up for more compact storage - might have to do a little engineering to make sure that add-on is strong enough - just a thought!

Great design I like it!!