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Step 9Assembling leg #1 to the top
There are definitely bunches of ways to do this. As I was the Lone Ranger for most of this project, I had to figure out a way to do it alone. Here ya go!
BIG NOMENCLATURE NOTE!
Left and right are always as seen from standing by the workbench and looking straight at the top of the saw horse.
The long point refers to the longest dimension of the angled bottom of the leg.
Set up
Install a screw pilot for a 3" drywall screw in one hand held electric drill, and a #2 Phillips bit in the other. The screw pilot need only extend about 2 inches or so, not the full length of the screw.
Plug both drills in and set them to the side.
Cut four pieces of 1/4" plywood about 2" x 6" to be used for shims.
Set a large hand screw clamp to one side.
Set one of the Free Bonus #2 wedges to one side (This will support the top while it is screwed to the first and third legs.)
Assembly
Set the leg on two of the 1/4" plywood shims with the long point down! Position it so the top of the leg is accessible to the electric drill. Clamp it to the table across one corner.
Apply glue to the top (square end) of the leg.
Place the top on edge, with the left end about half way up the wedge.
Place the other end of the top on the leg so the lip is resting on the top face of the leg, and both the end of the top and the side of the leg, are aligned.
Holding the top against the leg so the angle is square and flush, drill a pilot hole about 3-1/4 inch from the end and about one half inch up from the work table.
While still holding the top against the leg, insert a screw into the pilot hole, and using the other drill, sink the screw. The top of the screw should be below flush. You can now let go of the top.
Drill two more pilot holes at approximately the top two corners of the leg and put them in at an angle! The screws will hold better if they are slightly cross grain rather than parallel to the grain like the first one. Please see the pictures for a better idea.
Be sure the top is pulled flush against the top of the leg.
BIG NOMENCLATURE NOTE!
Left and right are always as seen from standing by the workbench and looking straight at the top of the saw horse.
The long point refers to the longest dimension of the angled bottom of the leg.
Set up
Install a screw pilot for a 3" drywall screw in one hand held electric drill, and a #2 Phillips bit in the other. The screw pilot need only extend about 2 inches or so, not the full length of the screw.
Plug both drills in and set them to the side.
Cut four pieces of 1/4" plywood about 2" x 6" to be used for shims.
Set a large hand screw clamp to one side.
Set one of the Free Bonus #2 wedges to one side (This will support the top while it is screwed to the first and third legs.)
Assembly
Set the leg on two of the 1/4" plywood shims with the long point down! Position it so the top of the leg is accessible to the electric drill. Clamp it to the table across one corner.
Apply glue to the top (square end) of the leg.
Place the top on edge, with the left end about half way up the wedge.
Place the other end of the top on the leg so the lip is resting on the top face of the leg, and both the end of the top and the side of the leg, are aligned.
Holding the top against the leg so the angle is square and flush, drill a pilot hole about 3-1/4 inch from the end and about one half inch up from the work table.
While still holding the top against the leg, insert a screw into the pilot hole, and using the other drill, sink the screw. The top of the screw should be below flush. You can now let go of the top.
Drill two more pilot holes at approximately the top two corners of the leg and put them in at an angle! The screws will hold better if they are slightly cross grain rather than parallel to the grain like the first one. Please see the pictures for a better idea.
Be sure the top is pulled flush against the top of the leg.
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Jun 25, 2010. 4:08 AMiMakeItHappen
says:
I really like this and will be making them this weekend, but i just wanted to know what is the purpose of the shims? thanks in advance for helping me out
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Jun 25, 2010. 8:43 AMMikey D (author)
says:
The shim is there to hold the leg parallel to the table top. The top piece of the saw horse in that position needs the leg to be lifted off of the table just a bit so the shim helps out. Take a look at the fourth, seventh and ninth pictures. Hope it helps! Mikey
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