Introduction: Saw Horse (Mast Horse)
Sea Horse (Saw Horse). Different criteria to hold a sail boat mast off the ground so you can work on it safely. Masts can easily be 600lbs! They can be lowered too fast as well. Made of 2x6 cedar as they live outside. With a wide, planed flat top to spread mast weight and wide feet not to sink in soil they are wobble free and very strong. Not as heavy as they look! I use 3 of these for a mast. Not seen anything as robust or wobble free on the internet. Most regular saw horses don't survive and the mast ends up on the ground. Hope you love compound angles as they add a lot of strength!
Ideally use a table saw to cut the block angles at the top. All joints are waterproof glue and all screw holes pre-drilled. Material costs $45 each.
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Step 1: Construction Details
Start with the angled block. Glue two 16" 2x6 pieces of cedar, flat sides together. Set table saw to 23 degrees and angle the sides in keeping as much width at the top as possible. Cut in half to make 2 blocks.
Cut 4 legs 37.5 inches long, angle top and bottom at 23 degrees with table saw. Cut 2 cross supports 29.25 inches long and 1 top strut 30 inches long.
Assemble one end of the saw horse flat on a table to mark the mortise for the cross support. Cut out the mortise to the full depth of the cross piece angled properly.
You can now pre-drill the holes and glue all joints with Titre Bond III waterproof glue. Use construction screws to assemble.
Cutting the compound mitre for the diagonal supports is easier if you fold paper to get the angle. The end angle is 23 degrees. Measure the length carefully then add an inch and shorten gradually for a precise fit.
Add the two top supports either side of the top support, measure to make snug. There will be 2.5 inches of the angled block supporting them. Pre-drill, glue & screw them on & plane the top flat, you are done!
Add cut preservative to the bottom of the feet & when dry paint the bottom 3 inches with a sealing stain for added longevity. Finished height is 36 inches.