42"

34-1/2"
18"

NOTE: Due to the style of joinery

used in this project, glue is not
necessary if joints are tight.
Glue can be used if desired. 30-1/2"

Materials Tools
QTY Rough Dimensions Rough Length Finish Dimensions Finish Length Notes Table Saw Router
4 3-1/2” x 5-1/2” 3’-0” 3” x 5-1/2” 2’-9-3/4” Vertical Legs Miter Saw Drill
Band Saw Hand Tools
2 2” x 3-1/2” 3’-0” 1-3/4” x 3-1/2” 2’-8” Trestle (*Note: 1-3/4” Finish Dimension)
Thickness Planer
2 3-1/2” x 3-1/2” 4’-0” 3-1/2” x 3” 3’-6” Top
4 3-1/2” x 3-1/2” 2’-0” 3-1/2” x 3-1/2” 1’-6” Feet
24 2” x 2” 2’-0” Taper 0”-1/2” 6” Hardwood Wedges

Craftsman Sawhorses Overview 1

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 2-1/2" 4"
1/4" 1/4"
3/8" 3/8" 1-1/2" 1" 1-1/2"
Kerf Cuts

1/4"

3"

3"
1/2” Roundover

Relief Holes

Side Front
1-1/2”=1’-0” 1-1/2”=1’-0”

33-3/4"
28"
28"
1/2” Radius 4"

3-1/2"
Tapered
Mortise
1-1/4"

1'-0"

12"
3-1/4" 3-1/2"
3”

3"
3-1/2"

3-1/4"
1/4"
1/2” Roundover

2-3/4"
4" 2-3/4"
1" 1" 3/8" 3/8"
3" 1" 5-1/2"
3/4" 3/4"

Notes: Legs - 4 Pieces

1. Kerf cuts should be approximately 3/8 from edge of tenon.
2. Drill 3/16” holes approximately 1/4” from shoulder as a relief for the kerf cuts.
3. Use 1/2” roundover bit at top shoulder as shown.
4. Ease all edges (not mortises, tenons or shoulders) with 1/8” roundover bit.
5. NOTE: Mortises are tapered as shown. Wedges driven into kerfs during assembly will tighten joint.

Craftsman Sawhorses Legs 2

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 32" 1-3/4"
1-1/4"
4" 24" 4"
1/4" 1/4"
1/4"
1/4"

3/8"

1/4"
Relief Holes Kerf Cuts
3-1/2"

3-1/2"
3"

3"
1/4"
3/8"
1/4"

Front Side
2”=1’-0” 2”=1’-0”
32"
1-1/4"

24"
1/4"

4"
1-3/4"

Top
1/4"

2”=1’-0”

Notes: Trestle - 2 Pieces

1. Kerf cuts should be approximately 3/8 from edge of tenon.
2. Drill 3/16” holes approximately 1/4” from shoulder as a relief for the kerf cuts.
3. Ease all edges (not mortises, tenons or shoulders) with 1/8” roundover bit.

Craftsman Sawhorses Trestle 3

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 42"

6" 3" 24"

2-1/2”

Tapered Mortise
3-1/2"

1/2"
1/2” Roundover
Front
1"

2-1/2" 2”=1’-0”
5-1/2" 3" 24"

1/2"
1"
3"

1"
1"

5-1/2" 3" 24" 3" 5-1/2"

1/2" 1/2" Bottom

2”=1’-0”

Notes: Top - 2 Pieces

1. Use 1/2” roundover bit at bottom corners as shown.
2. Ease all edges (not mortises, tenons or shoulders) with 1/8” roundover bit.
3. NOTE: Mortises are tapered as shown. Wedges driven into kerfs during assembly will tighten joints.

Craftsman Sawhorses Top 4

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 3-1/2" 6"
18" 1"
3" (Varies)
1-1/4" 1-1/4"
2"
1-1/4"

1-1/4"
2" 1-1/2" 4" Tapered Mortise
3/4"
3-1/2"

3-1/2"

2"
4-1/2"
2-1/4"

2-1/4"

3/4"
6" 6" 6" Mortise Depth Line
(varies depending on

5/16"
Front Side location)
Cut Line
2”=1’-0” 2”=1’-0”
1"

4"
3-1/2"

4-1/2"
6" 6" 6"
18"

Bottom
2”=1’-0” Notes: Wedges - 24 Pieces
1. Cut wedges 2” longer than the tenon and taper from
Notes: Feet - 4 Pieces
0” to 5/16” over the depth of the mortise.
1. Ease all edges (not mortises, tenons or shoulders) with 1/8” roundover bit. 2. Mortises vary in depth depending on location. Verify
2. NOTE: Mortises are tapered as shown. Wedges driven into kerfs during assembly will tighten joints. that wedges are 5/16” at depth of mortise.

Craftsman Sawhorses Feet and Wedges 5

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