The ultimate, heavy duty, stackable, bullet proof, extreme saw horses!

Step 5 Cutting the Tops

In order to make the horses stackable, each top is 1/2 inch longer than the preceding one. This is actually much easier than it sounds.

In theory, the tops could all be the same length and the horses should still stack. In practice they will vary a bit and you will still need to number the horses to stack them. Plus they will be very snug and difficult to get apart. Yes, the first set I made were all the same length.

Another option was to splay the legs out 5 degrees or so, but that would have added another degree of complexity so I chose the K.I.S.S. option in this case.

You will need three small pieces of half inch shim stock for spacers. they should be around 1-1/2 inches x 2-1/2 inches (or anything close.) I didn't have half inch plywood, so I used six pieces of quater inch ply. The quarter inch plywood also came in handy later.

You are going to set your fence stop at 36-1/2 inches and make the first cut. Then add one half inch of shim against the stop and make your second cut. Add another one half inch of shim for the third, and the last half inch of shim for the fourth top cut. Be sure no saw dust collects between the shims for the most accurate cuts.